request for proposal for establishment of
TRANSCRIPT
REQUEST FOR PROPOSAL FOR ESTABLISHMENT OF
AUTOMATED CONTINUOUS CLEANING FACILITY
ISRO PROPULSION COMPLEX
Indian Space Research Organization
Department of Space, Government of India
Mahendragiri 627 133
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CONTENTS
S.N Description Page No.
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1 Introduction 3
2 System Objectives and Configuration – Mechanical system 5
2A System Objectives and Configuration – Instrumentation system
6
3 Location and Lay-out of ACCF 9
4 Scope of work –Mechanical system 10
4A Scope of work – Instrumentation system 18
5 Execution Schedule 40
6 Phase of work 41
7 Warranty 43
8 General Conditions 45
9 Instructions to Bidders 63
10 Price Details- Mechanical system 77
10A Price Details –Instrumentation system 78
VOLUME-II
1A Specification of Mechanical Systems 82
1B Specification of Electrical Systems 115
1C Specification of Electronics Systems 118
2 Fabrication, Erection and Commissioning 176
3 Safety, Reliability and quality assurance 182
4 Documentation 186
5 Sub-Vendor Directory – Mechanical systems 188
5A Sub-Vendor Directory – Instrumentation systems 194
6 Glossary of acronyms, abbreviations and icons 198
7 Annexures
I- Iso-metric equipment layout
Attached Separately
II - Location layout
III- P&I Diagram
IV-System requirements of ACCF
V-List of equipments
VI-Quality Assurance Plan
VII-Scheme of line numbers of fluid circuit.
VIII-Scheme of tag numbers
IX- Different Performa
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VOLUME I
AUTOMATED CONTINUOUS CLEANING FACILITY
(ACCF)
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1. INTRODUCTION
ISRO Propulsion Complex (IPRC), Indian Space Research Organization (ISRO),
Department of Space, Government of India, Mahendragiri 627133, Tirunelveli
District, Tamil Nadu State, India (herein after referred to as “Department”) intends
to establish Automated Continuous Cleaning Facility at their premises. The facility
is intended to perform the IPA spray cleaning of the test object.
The Department seeks Proposals for Automated Continuous Cleaning
Facility (fluids are IPA and Gaseous Nitrogen) from capable Bidders. The
Department will organize pre-bid meeting on 20/09/2019 with the potential
Bidders after issue of Tender notice, to facilitate proper understanding of the
requirements and assessment of the site conditions. The potential Bidder’s
should participate in the pre-bid meeting. Non-participation of Bidder in the pre-
bid meeting will render their bid invalid.
The Bidders shall submit the bids in 2 parts viz
(i) Techno-commercial (non-priced) bid and
(ii) Price bid.
The Department will initially open the techno-commercial bids(Any price
detail should not be present in this part otherwise bid will be invalid) received to
evaluate the capability of Bidders with regard to the criteria specified in the RFP
and short-list capable bidders. The Department, if necessary at their own discretion,
will organize post-bid techno-commercial meeting with the short-listed Capable
Bidders. The Department will evaluate the techno-commercial bids and identify the
Suitable Bidders whose techno-commercial bids are complaint with the RFP
specification and place them on equal footing. The Department will open the price
bids of the Suitable Bidders only, hold post-bid price discussion, if necessary at their
own discretion, and award the Contract based on the lowest-priced bid.
The execution period reckoned from signing of the Contract to final acceptance
of Automated Continuous Cleaning Facility is 10 months.
Some of the key terminologies used in this document are defined as follows:
“Department” shall mean and include the President of India acting through
the Director, IPRC and any representative(s) of the Department duly
authorized on his/ her behalf.
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“Contractor” shall mean the individual or firm or company, whether
incorporated or not, chosen by the Department among the Bidders to this
RFP, undertaking the work and shall include the legal personal
representatives of such individuals or the persons composing such firm or
company or the successors of such firm or company and the permitted
assignee of such individual or firm(s) or company.
“Party” shall mean the signatory to the Contract i.e. Department or
Contractor or both.
“Sub-contractor” shall mean individual or firm or company whom the
Contractor engages for outsourcing certain service(s) related to the Contract.
“Sub-vendor” shall mean individual or firm or company from whom the
Contractor purchases certain material(s) related to the Contract.
“Contract” shall mean the formal agreement to be executed between the
President of India and the Contractor whom the Department may choose
based on the documents forming this RFP and acceptance thereof by the
Contractor and together with the documents as referred to therein including
the specifications, designs, drawings and instructions issued from time to
time by the Department.
“Date of Contract” shall mean the date on which the Contract becomes
effective with signing by all the Parties.
“Site” shall mean the land and or other places at Mahendragiri on which
work is to be executed under the Contract which is to be allotted by the
Department for the purpose of carrying out the work.
“Test object” shall mean the test article which is to be automated continuous
cleaned and is under the scope of Department.
“Material” shall mean all the goods/ items required for realizing and
forming the automated continuous cleaning Facility including raw materials,
semi-finished & finished products & sub-assemblies & assemblies which are
manufactured by the Contractor or their Sub-contractor(s) or bought-out from
their Sub-vendor(s).
“Service” shall mean all the activities performed by the Contractor for
realizing the Automated Continuous cleaning Facility including design,
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detail engineering and onsite construction, fabrication, erection &
commissioning.
“Specification” shall mean collectively all technical specification, terms and
conditions contained in this document
“Final acceptance” shall mean acceptance of the entire Automated
Continuous Cleaning Facility by the Department from the Contractor upon
successful completion of all contractual obligations by the Contractor and
commissioning including Performance Test.
“RFP” shall mean this Request for Proposal document
2. SYSTEM OBJECTIVES AND CONFIGURATION-MECHANICAL SYSTEM
The objectives to be complied with by the systems and the configuration to which they are designed are as follows.
2.1. Automated Continuous Cleaning Facility
The overall layout of equipments is given in the isometric layout for the Automated continuous cleaning Facility (ACCF), given in Annexure I. The ACCF is intended for cleaning of test object. It comprises following circuits
IPA circuit. GN2 circuit.
2.1.1. IPA system IPA system is used to clean the test object. Initially, IPA bought in 25L cans is used for filling of 500L container from which IPA will be pumped into the run tank. .Thus, the IPA required for cleaning of test object shall be stored in 3000L capacity run tank. Subsequently, the IPA will be sprayed inside the hardware (test object). The IPA will then be collected and fed back to the run tank for continuous operation of cleaning cycles. This process continues till the particle contamination of the test article achieves certain level i.e. Class 4 of SAE AS 4059
E & for oil contamination is ≤ 3mg/m2. 2.1.2. GN2 system
GN2 stored in 7 nos. of 1 m3 cylinders is regulated to the required low pressure and made to pass through a heater wherein a number of heating coils are placed. Thus, the heated GN2 (323K approximately) is used for
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pressurization/compression and depressurization/decompression to remove moisture from IPA cleaned test object. Venting rate is 40 g/s.
GN2 supply from 7 nos of 1 m3 cylinders (already installed at site) will be
used for EP valves command and purging of test object.
2A. SYSTEM OBJECTIVES AND CONFIGURATION - INSTRUMENTATION SYSTEM
The primary objectives of the Automated Continuous cleaning facility are as
below to perform closed loop operations of cleaning facility to facilitate time bound, error free & efficient operation. The proposed instrumentation system is to be built with PLC based controllers with I/O.
a) Instrumentation system
PLC based measurement, Command and control system is designed to meet the
aforementioned process and requirement of the facility and is dealt in this
report. The Instrumentation system caters to the requirement of monitoring,
controlling and recording the various process parameters during cleaning
phases.
PLC based measurement, Command and control system: It does the function of
commanding & controlling of Electro Pneumatic (EP) Valves and Pumps. It is
also required for measuring & monitoring of process parameters such as
Pressure, temperature, flow and level. The analog input parameters are
digitized and digital data are transferred to PC for storage, real time monitoring
and off-line processing.
Configuration
The system is configured using Programmable Logic Control. PLC consists of
main processor and I/O node. The SCADA node or operator station,
Programming node and Data storage node are located in instrumentation room.
SCADA node is used for manual commanding and the valves status is
displayed in mimic, programming node is used for programming and data
storage node is used for data storage and displaying of process parameters. The
fluid system will be shown pictorially using mimic diagrams in SCADA nodes.
Commands are generated manually from SCADA node or through auto
sequencing and communicated to the I/O module. This command signal is
interfaced to electromagnetic relays which are used to drive the solenoid valve
to actuate the E/P valve. For pump control valve operation, the command signal
from PLC is interfaced to isolators and in-turn actuates the pump actuators.
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The system is designed to control and acquire all digital and analog
inputs/Outputs with 500 msecond cycle time. However, the system has
provision to acquire at different sampling rates with 500 ms/ 1 s/ 5s resolution
to enable longer duration acquisition. The acquired parameters can be further
processed and viewed in required print format with suitable printing and
averaging intervals. All data are acquired by the PLC and raw data are sent to
the storage node for on-line display and data storage. For data processing
database containing details of all digital/analog channels such as tags,
description, channel address, unit, range, gain, offset, sensor constants will be
created. This database is used for processing and printing of parameters from
the raw data. All the processed data and raw data are stored on DVD as back up
for future reference. The specification of control system is given in Volume-II.
The operator station/SCADA node and data storage node (all in one pc with 24
inch monitor) have Ethernet ports interfaced to programming node through
High speed Ethernet switch in Client-Server configuration. The Programming
node communicates with PLC through switch for data transfer. The SCADA
node have necessary SCADA package for online monitoring of operations and
process parameter in different mimic diagrams. The SCADA package has
necessary standard library and tools for building functional blocks and symbols,
so that mimic page can be developed depending upon the various requirements.
Typical features of PLC based measurement, command and control system
Cycle time 500 msecond
Hardware clock =100 msecond
SCADA based operation
PLC based PID loops
Data Acquisition, Retrieval & Processing
MIMIC updation better than 1 sec
Analog Acquisition : 500 ms /1s/5s
Auto sequence command generation with 500 ms interval
Abort sequence with conditional based logics and Safety Interlocks
The figure-1 gives the configuration diagram for PLC based Control System.
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Controller I/O modules
PLC
N/W Switch
Programming Node
SCADA NodeData storage
nodePrinter
Isolator Barrier
Isolator Barrier
Isolator Barrier
Isolator Barrier
Pr. & Level Tx.
Temp Tx. Flow Tx. Guided wave radar based Level sensor
Temp. Sensor
Flowmeter
Relay Status Barrier
Relay Status Barrier
E/P Valve Pump Control
MEASUREMENT SYSTEM CONTROL SYSTEM
Figure-1: Configuration diagram for PLC based measurement, command and control system
Measurement system
The measurements cater to the requirement of measuring, monitoring
and recording the facility fluid system parameters like pressure, level,
temperature and flow. These parameters should also be viewed in the
instrumentation room. Field element of the entire Automated Continuous
Cleaning Facility Instrumentation system is given in table-1.
Total quantity indicated in the price format includes spares apart from the
above requirements.
Table-1: Automated Continuous Cleaning Facility Instrumentation
Requirements
SL. No. Description Quantity (Nos.)
1. E /P Valve 5
2. Pump monitoring and control for 2 pumps
3. Pressure Transmitter 16 AP-13 nos. & DP-3nos.)
4. Guided wave radar based non-
contactable level sensor
1
5. Temperature 5 (RTD Probe-2nos. &
Surface RTD-3 nos.)
6. Flow 2
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3. LOCATION AND LAY-OUT OF ACCF
3.1 Geographical location of Mahendragiri
Mahendragiri is situated in Tirunelveli district, Tamil Nadu state, India. The nearest major town is Nagercoil, which is 25 km southward and another town called Valliyoor, which is 15 km northward. It is aside the Kanyakumari- Madurai National Highway (NH 7) at a distance of 25 km northward from Kanyakumari.
The nearest international airport is at Thiruvananthapuram (Trivandrum)
in Kerala state, which is 90 km away in south-west direction. The nearest seaport is at Thoothukudi (Tuticorin), which is 100 km away in north-east direction. The seaport at Chennai (Madras) is 600 km northward.
3.2 Layout of Automated Continuous Cleaning
The Automated Continuous Cleaning Facility is about 1.5 km from the Main gate of IPRC. The location layout (given in Annexure II) gives the relative location of facility w.r.t. nearby buildings.
The hardware will be housed in the cleaning bay of existing Surface
Cleaning Facility in respective CUS and C25 bays. The filtration circuit is placed behind the CUS cleaning bay. The regulation circuit is located behind the C25 cleaning bay. The Automated Continuous Cleaning Facility will be provided with a proper shed on column supports. The Control system is located behind the IPA Storage Room of Cryo Surface Cleaning Facility.
The GN2 high pressure cylinders are to be installed on a trailer besides
the C25 bay of Cryo Surface Cleaning Facility at a height of 0.5m (approx). The GN2 control components shall be placed outside the continuous cleaning bay. Necessary openings on the wall are to be made by contractor for laying out the pipelines and cables.
3.3 Climatic conditions
The climatic condition at Mahendragiri is tropical and windy .Normal monsoon period is June-July and October-November. The Climatologically data for Mahendragiri is as follows: Rainfall
Maximum daily rainfall : 50 mm
Maximum monthly rainfall : 120 mm
Average annual rainfall : 550 mm
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Temperature
Maximum temperature in shade : 311 K
Minimum temperature : 293 K
Humidity
Maximum relative humidity : 80%
Minimum relative humidity : 25%
Type of climate : Tropical
4. SCOPE OF WORK-MECHANICAL SYSTEM
The scope of the work and the demarcation of responsibilities between the department and the contractor in the realization of fluid servicing system for Automated Continuous Cleaning Facility are given in this section.
4.1 Scope of services by the department
In order to realize the Fluid servicing system for ACCF, the department
will provide the following services. 4.1.1 Configuration of the FSS
The preliminary design of the system has been done by the department. Process and Instrumentation Diagram (Ref ANNEXURE-III) with the specifications of the fluid circuit components (Ref section 1, Vol.II) are given in this document along with the specification of the system requirements (ANNEXURE-IV).
The list of equipments is given in ANNEXURE-V. These details are
considered adequate for price estimation. Upon award of the contract, the
Department will furnish the design document for review by the Contractor.
The department will convene a design review meeting after awarding the
contract.
4.1.2 Preliminary layout drawings
The department has made a preliminary isometric layout drawing of the fluid service system (Annexure-I). The Updation of the above can be done according to the site condition and fabrication easiness.
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4.1.3 Review of detail engineering
Upon award of the contract and after design review, the contractor shall carry out detail engineering. The scope of work to be done by the contractor under detail engineering is given in section 4.2.2.The department will review the detail engineering done by the contractor.
4.1.4 Major civil works
The Department will provide the following major civil works:
Approach roads. ACCF Buildings, fluid servicing area & control room
4.1.5 Services during erection and commissioning
During erection and commissioning, the Department will provide the following services:
Electricity for onsite erection on chargeable basis at the tariff rate prevailing at the time of consumption (existing tariff rate is Rs. 8/kWhr).
Process fluids such as IPA and GN2 for commissioning at free of cost.
4.2. Scope of work by contractor
The scope of work to be done by the contractor for the realization of FSS is given in this section. The bidder shall submit a complete bid for the entire works mentioned herein as per the formats specified. 4.2.1 Design review
As stated in section 4.1.2/volume-I, the P&ID is given in this document. Upon award of the contract, the Department will submit, to the contractor, the design document with detailed calculations and the sizing of the fluid circuits comprising the pipe-lines, flow components, instruments, etc. The Department will organize a design review meeting in which the contractor’s representative(s) shall participate.
The objective of the design review is to arrive at a consensus between the department and the contractor on the design of FSS and to freeze the input data for the detail engineering to be done by the contractor.
However, in case of dispute between the department and the contractor, the details of fluid circuits, comprising flow components, instruments, etc, specified in the contract shall be final.
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The design calculations are based on the codes/ standards mentioned in various sections of this document. In case the contractor prefers to employ alternative codes/ standards, the Department may agree, provided that the sizes of the fluid circuits chosen as per the alternative codes/ standards are equal to or the next higher standard ones than those specified in the contract. In such case where the contractor employs alternative codes/ standards, it shall be their responsibility to submit a copy of such codes/ standards in English language to the Department during design review. The design review shall primarily address the following issues:
Design of P&IDs to comply with specified functional requirements Adequacy of the sizes of fluid circuits, comprising pipe-lines, flow
components, instruments, etc to comply with the specified process parameters and operations.
Adequacy of the in-built safety features
4.2.2 Detail engineering
Based on the approved design evolved during design review, the contractor shall carry out detail engineering, which shall comprise the following:
a. Design of joints: The drawings of conventional, standard, removable
joints (threaded unions, flanges, etc.,) along with the seals (gaskets, O-rings, etc) and the edge preparation details of welded joints shall be provided.
b. Pipe-line lay-out: The detail lay-out (top view) drawings (indicating
skeletal dimensions and to scale) of the pipe-lines of the process fluid circuits shown in the P&IDs shall be provided. Pipe line layout shall be prepared in such a way that dead volume shall be kept as minimum as possible and the details of dead volume & their effects shall be presented during review.
c. For the sake of better legibility, segmental pipe-line lay-out drawings
shall be made in convenient numbers of segments of any area showing all the pipe-lines in a magnified scale. The drawings shall be made on appropriate software and provided in compact discs (CDs) along with one hard copy.
d. Pipe-line isometrics: The 3-dimensional isometric drawings of the
individual pipe-line segments shall be made along with clamping details. The drawings shall be fully dimensioned (not to scale) and show the locations of fittings, flow components, instruments, pipe supports, etc.
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Each isometric drawing shall contain the detailed Bill Of Materials (BOM). The drawings shall be made on appropriate software and provided in compact discs (CDs) along with one hard copy.
e. Estimation of pressure drop based on the pipe-line lay-out and isometric
drawings.
f. The detailed Quality Assurance Plan (QAP) for the materials such as pipes, pipe fittings, flow components, instruments, etc., fabrication erection and commissioning shall be provided.
g. Detailed procedure and acceptance criteria for fabrication, erection and
commissioning.
h. The purchase specification of the materials such as flow components, instruments, pipes, pipe fittings, etc shall be provided.
i. The list of sub-contractors (along with their company profile, technical
catalogues, etc) from whom the contractor has finalized to purchase the materials such as, flow components, instruments, pipes, pipe fittings, etc shall be provided.
j. The list of spares to be supplied shall be provided. The guidelines for
selection of spares are given in section 4.2.5. The contractor shall organize the Detail Engineering Review (DER)
meeting at their office/factory, in which the Department’s representative(s) will participate. 4.2.3 Selection of sub-contractors
The sub-contractors, who, in the opinion of the Department, are competent enough to supply the materials required for FSS are given in the directory in section 5/volume-II.
Upon award of the contract, during Detail engineering review, the contractor shall submit the list of sub-contractors with whom they have finalized to purchase the materials and services. This list of sub-contractors along with the purchase specification is subject to review by the department.
Nevertheless, the department’s proposal or approval of sub-contractor
shall not absolve the contractor’s responsibility to comply with the obligations of the contract.
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4.2.4. Purchase of materials
All the materials such as equipments, flow components, instruments,
pipes, pipe fittings are to be purchased by the Contractor. The general
specifications of the systems are given in Section 1/volume-II. The detailed
purchase specifications for the individual items of materials to be purchased
shall be made by the Contractor. The purchase specifications of such materials
and the sub-contractors from whom such materials are to be purchased are
subject to review by the Department.
4.2.5. Supply of spares The following spare shall be supplied along with FSS. The break-up
prices of the spares shall be given in the bid separately.
a. Spare components: Spare components shall be supplied as fully assembled (wherever applicable) stand-alone pieces. SS pipes shall be given 20% extra as spares and spare for flow components as given in Annexure V. These components are meant to be stored in the department’s inventory for facilitating future augmentation (not under the scope of the contractor) so as to comply with unforeseen requirements in future. These components shall also be subject to the same tests specified for the like components in the contract.
b. Spare parts and consumables for erection and commissioning: For the
materials used in the realization of FSS, contractor shall also supply the spare parts (like seat insert, body gasket, gland packing, plug stem assembly etc., for valves) and consumables like gaskets, PTFE tapes, etc, used during erection and commissioning.
4.2.6 Fabrication
The system shall be fabricated at the contractor’s factory to such an extent that they can be transported by rail or road. The system shall be divided in to different segments for this purpose. The remaining fabrication works shall be carried out at department’s site. All the consumables, tools, tackles, etc required for fabrication shall be arranged by the contractor. 4.2.7. Inspection
All the bought-out materials and the works during fabrication at the contractor’s factory shall be inspected by reputed third party inspection agency (TPI) like Lloyds, BV, TUV and inspection during fabrication & erection at the department’s site shall be done by department’s representative(s).
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The broad scope of inspection shall be as follows. However, the detailed
scope of inspection as given in the QAP (ANNEXURE-VI). a. Review of the fabrication drawing. b. Identification of the materials such as equipments, flow components,
instruments, pipes, pipe fittings. etc., and review of the test and calibration certificates, for compliance with the contract specification.
c. Witnessing of welding procedure qualification and welder’s performance
qualification tests. If the welders already possess the performance certificate, the TPI agency shall review and authorize the same.
d. Review of X-ray films of Radio-graphic tests for possible defects in the
weld joints. e. Inspection at any stage of fabrication to ensure that the methodology
employed for fabrication is in compliance with the requirements of standards/codes, practices, contract specification and the approved documents.
f. Witnessing of pressure test, leak test and cleanliness test of the system
during fabrication and erection.
It shall be the contractor’s responsibility to arrange for and co-ordinate with the TPI agency. TPI cost should be included in the basic price.
Upon completion of fabrication, the contractor shall provide the clearance
certificate signed by TPI agency. Upon satisfactory review of the test certificates and inspection reports of fabrication by TPI agency, the department will accord the shipment clearance. 4.2.8. Transportation
The fabricated system shall be properly packed and transported to the department’s site at Mahendragiri. The prices towards packing, handling, freight, insurance, clearance, etc are to be paid by the contractor and the details should be given in the bid. Upon receipt of the department’s site, It shall be the contractor’s responsibility to unload the materials/ fabricated system and to construct temporary sheds/ buildings for proper storage of the material /fabricated system to protect from the vagaries of nature.
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Imported items
The Contractor shall provide the list of items with cost break up to be imported. Custom Duty Exemption Certificate (CDEC) for availing concessional custom duty as per notification no. 5/2018 dated 25/01/2018 shall be provided by the Department only for items consigned to IPRC Mahendragiri against invoice submitted by the Contractor and concessional IGST as against notification no. 47/2017. Necessary exemption certificates shall be issued by IPRC as and when required. The Contractor shall be responsible for transportation of items from their factory’s site to Chennai seaport/Trivandrum airport. The Contractor shall be responsible for customs clearance and transportation of consignment from seaport/airport to IPRC, Mahendragiri.
4.2.8.1 PACKING
The Contactor shall pack the control system and its accessories and make
the identification names at the top of each pack with order/contract no.
Phytosanitary certificate: As per “Plant Quarantine (Regulation of Control into India) Order 2003”, articles packed with packaging material of plant origin viz. hay, straw, wood shavings, wood chips, saw dust, wood waste, wooden pallets, dunnage mats, wooden packages, coir pith, peat or sphagnum moss, etc. will be allowed entry by Customs (Department of India) only with a “Phytosanitary certificate”. Therefore, the Prime Contractor shall ensure that the consignment is accompanied by such a certificated issued by the Plant Quarantine authority in the country of origin; if any of the above-mentioned packaging material is used. In case of delay/denial in customs clearance (in India), the entire responsibility including additional expenditure shall solely rest with the prime contractor. 4.2.9. Erection
The system is to be erected by the contractor at the department’s site. The detailed specification for erection is given in section 2.2/volume-II.
The works done by the contractor during erection shall be inspected by department’s representative(s). The erection shall also include unloading, storage, cleaning & testing, minor civil & structural works (for grouting of equipments, pipe supports, cable trench, etc) and also the instrumentation system up to CTR.
The contractor shall arrange for constructing temporary sheds/buildings for storing materials, erection equipments, tools & tackles, site office, etc. The contractor’s personnel shall not be permitted to reside inside the department’s premises after the work. The contractor shall arrange for transportation, accommodation, food, health care, communication, etc for their personnel.
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Also during erection works at department site, the department reserves
the right to stop the work temporarily at any time in view of ongoing activities being carried out and the same will be communicated to the contractor at least one week advance. 4.2.10 Commissioning
The Fluid Servicing system of ACCF shall be commissioned jointly by the department and the contractor in 2 phases as follows:
Qualification test to validate the individual sub-systems in static (non-flow) condition with IPA and GN2 for respective systems where ever applicable.
Final acceptance test to validate the entire system in dynamic (flow) condition with IPA and GN2 where ever applicable.
4.2.11. Documentation
4.2.11.1 The Contractor shall submit the relevant documents during different
phases of the Contract as per the details given Sl. 4.2.2, Volume –I of this
RFP document for the respective systems. The documents are subject to
review by the Department. However, the Department’s approval shall not
absolve the Contractor of their responsibility to comply with the
specifications and obligations of the Contract.
4.2.11.2 All the documents shall be provided in English language only. In
the event that the documents by the Sub-contractors/ Sub-vendors are in
some other language, it shall be the Contractor’s responsibility to translate
them to English language.
4.2.11.3 The documents shall be provided in 1 hard print and in electronic
form (soft copy) in CD-ROM or DVD-ROM or through email.
4.2.11.4 Master Documentation: During final acceptance of ACCF, the
Contractor shall provide a consolidated repository of the latest versions/
revisions of all the documents generated/ used during the course of entire
contract execution. The documents shall be in electronic form on a common
platform from which any document shall be retrievable through user-
friendly front-end interface software. The platform and software shall be
compatible for installing in any computer or server of the Department.
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4.2.11.5 The Master documentation shall be exhaustive covering, but not
limited to, Contract & amendment (if any), FEED review report, Risk
analysis report, detail engineering documents & review reports, purchase
orders, general arrangement drawings of equipments, flow components &
instruments, pre-delivery inspection & test documents, invoices,
manufacturer’s instruction manuals for installation, operation, maintenance
& trouble-shooting, guarantee/ warranty certificates, construction/ erection
test & inspection documents, commissioning reports, PVTR execution report,
standard operating procedures, final acceptance certificate, minutes of
meetings, schedule charts, payment reconciliation statement, inventory of
spares with proper identification number correlating to their location in the
appropriate place, etc.
4.2.11.6 The following documents to be supplied for instrumentation system
4A. SCOPE OF WORK-INSTRUMENTATION SYSTEM
The scope of contractor for instrumentation system is briefed below
1) Detailed Engineering
2) Procurement of all items related to system realization by vendor.
3) Integration of hardware & Installation of all required software and Factory Acceptance Test (FAT) for control system.
4) Shipment of items to Department site and inward inspection of items at Department site.
As built version of all documents submitted during detailed engineering.
Software Diagnostic details
Software requirement document as per ISPD-2 (Template will be provided by department during detailed engineering)
Software design document (Flow Chart, Source code etc.) ISPD-2 (Template will be provided by department during detailed engineering)
Software Configuration Manual
Installation Manual for all Software
Installation Manual for Hardware
Operating Manual for Hardware and Software
Maintenance Manual for Hardware and Software
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5) Installation and commissioning of the system at Department site. Site Acceptance Test (SAT) for control system. Training at Department site
6) Operation and Maintenance support for a period of two years after SAT.
7) Annual Maintenance contract (non-comprehensive) for a period of three years.
4A.1 DETAILED ENGINEERING
a) The detailed engineering shall be done on the basis of finally agreed
control philosophy and Input/output List.
b) The following detailed engineering documents shall be provided
Finalized System Architecture and detailed configuration diagram
including all subsystems.
The specification/detailed catalogue of hardware, system software and
other packages proposed.
Selection of all major equipment including model matrix and sizing
sheets with supporting documents like latest catalogues.
The quantity and model/version number of hardware & software.
Instrument/equipment erection diagram, mounting procedure, cable
termination and ferruling details
Cable &Cable tray routing layout diagram
Pneumatic/Impulse tubes routing diagram
General assembly drawing of control system equipments in suitable
industrial standard rack for the integration.
Rack wiring & termination detail.
Networking scheme in cable terminal room & control room as per
configuration drawing using suitable network equipments and cables
with required drawing.
Power distribution schematic for control system and instrumentation
system.
Site requirement in terms of electrical power and space to the
Department.
Finalized FAT & SAT Procedures.
Software Life cycle model followed for software development.
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c) Supplier shall provide one copy of detailed engineering document in Hard
& Soft form to the purchaser for review and approval.
d) The soft copy shall be in editable version so as to enable modification in
future.
e) Only the purchaser approved document shall be followed for all further
commissioning activities.
4A.2 PROCUREMENT OF ALL ITEMS RELATED TO INSTRUMENTATION SYSTEM REALIZATION BY VENDOR.
All control, command and measurement system materials which are
required to meet the entire system requirement shall be supplied by
the vendor.
The procurement shall be made as per final approved specifications &
configuration decided during detailed Engineering.
The specification of the items which are not covered in this annexure
will be finalized and approved by the purchaser during detailed
engineering phase.
Detailed specifications of the above parameters are given in Volume-II.
4A.3 INTEGRATION OF HARDWARE & INSTALLATION OF ALL REQUIRED SOFTWARE AND FACTORY ACCEPTANCE TEST (FAT) FOR CONTROL SYSTEM
The system hardware shall be assembled and integrated as per
approved detailed engineering documents. The required
software shall be loaded.
Any software customization required to meet the specification
requirement shall be done in discussion with Department.
The control system as a whole shall be made ready at vendor’s
site for Factory Acceptance test.
4A.3.1 FACTORY ACCEPTANCE TEST (FAT)
After detailed engineering, custom software generation and loading,
the whole system simulation will be subjected to full functional test on
simulation basis of all inputs and outputs at vendor’s site before
shipment.
Therefore, the whole system will be completely assembled, wired and
staged for inspection and conducting the simulation test of 100% I/Os
as per FAT approved procedure during detailed engineering.
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Software document in line with ISRO standard (ISPD-2). Necessary
template for preparing the document shall be provided by the
department.
4A.4 SHIPMENT OF ITEMS TO DEPARTMENT SITE AND INWARD INSPECTION OF ITEMS AT DEPARTMENT SITE
After completion and acceptance of FAT, the whole control system package
and all material required for erection and commissioning shall be shipped
to Department site. Import items shall be delivered at C&F Trivandrum.
Indigenous item delivery point shall be FOR, Mahendragiri.
The packing cases shall be optimized in order to minimize the transport
costs.
A copy of instruction manuals for installation, operation & maintenance
shall be included in the cases.
Mobile parts inside the equipment shall be fixed tightly to the structure.
Special protection shall be used for fragile goods.
Particularly delicate items shall be further protected from shocks to
guarantee perfect stability during transport, by means of foam, rubber or
other similar materials.
Closed airtight polythene bags containing silica gel or other moisture
absorbents shall be used.
4A.5 INSTALLATION & COMMISSIONING OF THE SYSTEM AT DEPARTMENT SITE
This includes following and other activities related to
1. Positioning of shipped items at instrumentation room and cleaning
facility room.
2. Identification & verification of all individual components
3. Installation, erection and commissioning of PLC based
measurement, command and control system.
4A.5.1 Positioning
Vendor’s responsibility at site shall include the following activities
necessary to be performed to complete the job satisfactorily.
Transport of system from site stores to actual location.
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The Vendor shall be responsible for lifting, transportation and safe
custody of the equipment until completion of its installation and
acceptance by Purchaser’s representative.
Copies of instructions/manuals shall be handed over to the
purchaser’s Engineer.
I/O nodes, Control system, command system, measurement system
and Programming, SCADA & Storage nodes shall be positioned in
instrumentation room.
Control system equipment shall be located such that it is easy to
approach for operation and maintenance.
Instrumentation rack, Junction box, cables, cable trays, cable lying
from cleaning facility to instrumentation rack shall be scope of
Vendor.
4A.5.2 Identification & verification
Unpacking the system and inspection of the same for damages.
All equipments shall be inspected thoroughly by vendor for
completeness and proper functioning. Vendor must initiate the
remedial action to replace the faulty equipment or item with
intimation to Purchaser.
Each individual component (e.g. input/output modules, switch, etc.)
shall be identified by part/model number and serial number. The
documentation shall reflect these identification marks.
Racks / enclosures shall be labeled in front and rear for easy
identification.
All internal & inter-cabinet wiring shall be ferruled with permanent
markers bearing identifications that can be cross referenced with
appropriate documentation. Colored ferrules shall be used with
proper coding philosophy. Tag plate shall be provided for the cable
no. identification on the top of the related terminal strip in the
cabinet. Cross ferruling shall be done.
4A.5.3 Installation, erection and commissioning of PLC based measurement, command and control system.
Best engineering practices shall be followed to maintain high
standard of workmanship & quality in a neat and safe manner.
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Installation to be carried out as per approved detailed engineering
document.
All equipments, instruments, tools & materials required to carry out
the work shall be brought by the Vendor.
4A.5.3.1 Installation of control system
The control system shall be positioned.
Laying and termination of all inter panel earthing cables.
Ensure the correctness of control system hardware integration.
Ensure the loading of necessary software like system software,
application software etc.
The control system shall be powered ON.
4A.5.3.2 Functional checking of the control system
Vendor shall be responsible for loop checking which shall include
checking of the configuration, network interconnection from node to
PLC, I/O module to control system rack termination end and
ensuring over all system functioning.
Loop checking shall be carried out to check the functional
performance of all elements in the loop and thereby ensuring proper
functioning.
Inter system (control system functional check with field devices)
panel loop checking shall be carried out along with purchaser.
After completion of all functional tests as per specification, the
whole work shall be subjected to final inspection to ensure that start-
up trial can be commenced in the presence of Department Engineer.
If any defect is noticed, the Vendor shall arrange to rectify the
defects noticed.
4A.5.3.3 Erection and commissioning.
GENERAL INSTRUCTIONS
4A.5.3.3a Tools for erection and commissioning
The contractor shall bring necessary tools required for erection &
commissioning of the instruments & components and an instrument
work shop shall be made ready at the erection site.
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Erection & commissioning works shall be carried out strictly according
to the specifications stipulated in the contract, documents/drawings
approved by department during detailed engineering. Also it shall be
carried out as per the supervision of the department’s representative.
The Contractor shall provide and maintain a formal system for
documenting technical clarification from the Department.
Only correctly signed documents which are marked “Approved for
Construction” (AFC) shall be used for installation work.
Only the best trade practices and correct tools shall be used and all
works are expected to be completed in a neat and safe manner.
Welding shall be done only by qualified personnel.
Electrical installation shall only be performed by appropriate qualified
trade persons.
Holes shall be drilled or punched and not burnt out by gas torches or
electric arcs.
Piping and tubing shall be formed with the appropriate pipe or tube
bending equipment.
Instrument/equipment shall be mounted using suitable
stands/brackets/clamps. As far as possible all instruments shall be
mounted on instrument support stands. These shall be installed on
floors, RCC columns and walls using approved make anchor
fasteners/Hilti bolts and on steel structure by drilling suitable holes and
using chromium plated/galvanized bolts and nuts or in exceptional
cases by welding. After welding, the slag on weld surface shall be
removed and one coat of Red-oxide primer and two coats of paint shall
be applied over the surface.
Equipment shall be installed in a neat, workman like manner so that it is
level, plumb, square and properly aligned and oriented.
Instruments should not be supported from impulse lines, hand rails and
vibrating structures.
Instruments shall be located such that it is easy to approach for
operation and maintenance. Cover can be removed without obstruction
and there should not be any problem in re-glanding the cable later on.
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All indicating instruments shall be located such that its scale is
conveniently visible to plant operator.
Canopy shall be provided for all the instruments, JBs and SOV located
outdoor.
All threaded opening of the instruments shall be protected by suitable
Aluminium/Chromium plated plugs.
During installation of the signal and control cables and prior to
connection up to the instruments, the cables shall be checked for the
insulation resistance, continuity and tagging.
If the insulation resistance is not found within the limits, these cables
shall not be used. The contractor should lay new cables, meeting the
continuity and insulation resistance requirements, without any cost
implication.
The signal and control cable wires shall be connected to respective
terminals, as per the wiring drawings.
Equipment shall be properly grouped at a convenient location based on
the equipment layout diagrams.
Allocation of grouping of channels based on signal levels in junction
boxes and racks shall be finalized during detailed engineering.
Separate trays shall be used for routing pneumatic tubes and cables.
Field transmitters (pressure, temperature, Flow &level) shall be
mounted on 2” pipe stands. The instrument stands shall have a suitable
height so that instrument shall be mounted at 1.4m from ground or
platform / catwalk. If the instrument to be mounted on a catwalk /
platform the preferred location shall be on the outside of the hand
railing.
To protect temperature probes from mechanical damage /entry of
water, suitable individual enclosures shall be designed.
Handling and Storage instruments
The Contractor shall be responsible for the collection of “free-issue”
instrument items, transportation, storage and safe custody of the
equipment until completion of its installation and acceptance by
Department’s representative. Contractor shall maintain a stock system to
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enable material tracking throughout the installation & commissioning of
the facility.
All instruments shall be visually examined by the Contractor on receipt
to ensure that they have not been damaged in transit. Instruments shall
then be replaced in their original packing and housed in a separate
secure, dry, cool storage area provided by the department.
If any item is lost or damaged by the contractor, new item may be
procured and replaced by the contractor with their own cost or the cost
of the item will be deducted from the contractor’s bill.
When unpacking is necessary, care shall be taken to ensure that
accessories are not mislaid or mixed.
Instruments shall not be left lying around the construction area.
All covers and plugs on the instrument connections shall be left in place
until connections are used.
4A.5.3.3b Installation Preparation
SCOPE:
The scope involves procurement, installation & wiring of field elements
like absolute & differential pressure transmitters, temperature probes,
temperature transmitters, Mass flow meter along with transmitter,
impulse tubing, erection of cable trays, armoured/ un-armoured cable
laying, wiring of instrumentation rack and interfacing between racks.
Verify that instrument process connections ports before tapping.
Sensitive electronic instruments/components shall be protected during
welding, drilling & filing activities.
Metal Filing and metal or wood shaving shall be prevented from falling
on the components/ports/connectors.
Instrument stands and mounting brackets shall be fabricated according
to design drawings approved by the department.
Identification tags shall be attached to each field component bearing its
instrument number in accordance with P&I drawings/ Instrument
schedules.
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Nameplate shall be attached to junction boxes and racks. Name plates
shall be of stainless steel with black lettering shall be provided for
junction boxes. Nameplates shall be of plastic type for racks. The details
of measurements and control system are finalized during detailed
engineering.
4A.5.3.3b.1 Absolute Pressure and Differential pressure measurement
system
This measurement is used for monitoring the tank, fluid line pressure
and fluid level.
The SMART pressure transmitters (Absolute & Differential) with built-in
electronics sense the pressure and convert the sensed pressure to a
corresponding 4 to 20mA electrical signal.
The 4 to 20mA output is wired to isolator. Isolator is powered from 24V
DC Switch Mode Power Supply (SMPS) with low ripple. The isolator
and 24V DC Power Supply are housed inside instrumentation rack
located at instrumentation room.
The output of Isolator is given to PLC based Control system for
acquisition and monitoring.
Impulse tubing (12.7mm SS tube) is used for connecting the process to
the transmitter.
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Schematic diagram of Absolute Pressure measurement system
Schematic diagram of Differential Pressure measurement system
4A.5.3.3b.2 Guided wave radar based Level measurement system
Radar based level sensors are to be used for level of fluid (IPA)
measurement inside the collection tank.
The level is converted to a corresponding 4 to 20mA electrical signal.
The 4 to 20mA output is wired to isolator. Isolator is powered from 24V
DC Switch Mode Power Supply (SMPS) with low ripple. The isolator and
24V DC Power Supply are housed inside instrumentation rack located at
Instrumentation room.
The output of Isolator is given to PLC based Control system for acquisition
and monitoring.
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Schematic diagram of Radar based level measurement system
4A.5.3.3b.3 Temperature (RTD based) measurement system
This measurement chain is used for monitoring the surface& fluid line
temperature.
4 wire RTDs are used as sensors. The sensors are interfaced to temperature
transmitters.
The 4 to 20mA output of temperature transmitter is wired to isolator.
Isolator is powered from 24V DC SMPS. The isolator and 24V DC SMPS
with low ripple are housed inside instrumentation rack located at
instrumentation room.
The output of isolator is given to PLC based Control system for acquisition
and monitoring.
C
RACK
C
CONTROL SYSTEM JB
Radar based level s ensor
MU LTI
CO RE
PVC
CABLE
4-20mA
2 core pvcArmoured
cabl e
FIELD Instrumentation Room
2-10V
P ro ce ss
Lin e
ISOLATOR BARRIER
C – C o n n ecto rDP r.TX - Di ffere ntial Pre ssu re Tran smitte r
JB – Ju n ctio n B o x
24V DC,10A SMPS
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Schematic diagram of temperature measurement system
4A.5.3.3b.4 Flow measurement system
This measurement is used for measuring the flow rate in fluid lines. Mass flow meter is used for flow measurement. The 4 to 20mA output of flow transmitter is wired to isolator. Isolator is
powered from 24V DC SMPS. The isolator and 24V DC SMPS with low ripple
are housed inside instrumentation rack located at instrumentation room.
The output of isolator is given to PLC based Control system for acquisition
and monitoring.
Schematic diagram of flow measurement system
ISOLATOR
BARRIER
CO
NN
EC
TO
R
C
CONTROL SYSTEM JB
TEMP.
TXMULTI
CORE
PVC
CABLE
4-20mA
2 CORE PVC
ARMOURED
CABLE
FIELD Instrumentation Room
2-10V
RTD
SENSOR
4 CORE
PVC CABLE
24V DC,10A SMPS
RACK
C – ConnectorTEMP.TX - Temperature TransmitterJB – Junction Box
C
RACK
C
CONTROL SYSTEM
JB
Mass Flow meter
with TX.
MULTI
CORE
PVC
CABLE
4-20mA
4 CORE PVC
ARMOURED
CABLE
FIELD Instrumentation Room
2-10V
Process Line
ISOLATOR BARRIER
C – ConnectorJB – Junction Box
24V DC,10A SMPS
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4A.5.3b.5 E/P valve Command
SCOPE:
The scope involves procurement, installation & wiring of field elements like
SOV, pneumatic tubing, erection of cable trays, cable laying on cable trays,
wiring of instrumentation rack and interfacing between racks. List of E/P valves
is tabulated below.
Command Chain Diagram of EP Valve is shown in Figure
A single valve operation calls for enabling digital output from PLC. The digital
output drives electromagnetic relay which provides normally open (NO)
contact. The output from the relay output drives the solenoid coil.
Process/Simulation mode: System can be selected in process/simulation
(PRO/SIM) mode for the command chain from SCADA node using hardwired
PRO/SIM switch. PRO/SIM switch is with dual contact. In the process mode,
solenoid valves are commanded to Open/Close based on PLC output and
voltage is available to operate the valve. In the simulation mode, solenoid valve
power supply is inhibited at relay contact and hence voltage is not available to
operate the valve. In both the cases command issue information is available in
the SCADA node through relay auxiliary contacts. The command
acknowledgement and valve status are acquired through digital input card of
control system. The open/close indication of the E/P valve is provided on
mimic on SCADA node by green/red color corresponding to valve field status.
PRO/SIM change over relay which is energized in process mode routes
24V field power supply through relay contact which is energized through PLC
output for valve operation. Second relay contact is used to confirm the
command execution status and displayed in mimic diagram.
In the Process Mode, relay PR1 is actuated. One contact of PR1 is given to
relay C1 Contactor for linking the field power supply to valve driver relay. The
other contact of PR1 relay is fed to DI card for PRO/SIM feedback indication.
When valve actuation command is generated from PLC Digital Output R1 valve
driver relays is actuated. The contacts of R1 relay are closed and Solenoid Valve
is actuated. In Simulation mode, the relay PR1 are not energized hence 24V DC
is not available for energizing Solenoid Valve.
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JB
Multi core
PVC cable
4 core PVC armouredcable
OFF Status
RELAY
STATUS BARRIER
24V DC SMPS
Command
COM.ACK
Field Instrument Instrumentation room
C
C C
C C
CONTROL SYSTEM
24V DC SMPS
Multi core PTFE cable
Status Switches
EP Valve
ONStatus
C – ConnectorJB – Junction Box
RACK
RACK
Solenoid
E/P valve status reception: For E/P valve switch status reception, 2 channel
Isolator is used in between field status switch of E/P valve and Digital Input
(DI) card of control system. Each isolator provides 2 sets of potential free
contacts, which is activated based on status inputs from the EP valve. Common
point of potential free contacts (Open and Close) are connected to +24V DC
Power Supply. ‘NO’ contacts are connected to DI card of Control System for
status reception. switches are used in field EP valves for status. Command
execution status is displayed by SCADA software of the PLC.The specifications
of relay, power supply and isolators are given in Volume-II.
E/P Valve chain diagram
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POWER SUPPLY
ACK PS
+ -
PROC/SIM FEEDBACK
COMMAND
CONTROL SYSTEM RACK
PROCESS/SIMULATION
SWITCH
DI
DO
DI
CONTACTOR
EP VALVE COMMAND RACK
FIELD
C
SOLENOID
-+
DI –DIGITAL INPUTDO – DIGITAL OUTPUT
ACK – ACKNOWLEDGEMENTPS – POWER SUPPLY
FIELD PS
+ -
CONSOLE
COMMAND ACK
PR1
C1
R1
SOV
E/P Valve chain wiring diagram
E/P Valve status
Sl. No. E/P
Valve
Interlock
1. LVP701 Normally open, to be closed when IPA cycles are over. At initial
status should be checked for open, then only cleaning to start.
2. LVPA02 When run tank is full and pump is ready to switch on, to be
opened.
3. LVPA03 After 2 mins spraying at initial, to be opened.
4. LVP709 When temperature of LTI (Temperature probe) reaches 50 degree C,
It will be opened and when cleaning tank pressure reaches 300
mbar (Gauge pressure) it will be closed.
5. LVP710 When tank pressure reaches 300 mbar (Gauge pressure), LVP709 to
be closed. Tank pressure remains 300 mbar for 15 minutes.
Thereafter, LVP710 to be opened until tank pressure reaches 50
mbar (Gauge pressure).
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4A.5.3.3b.6 PUMP CONTROL BASED COMMAND SYSTEM
Pump control is used for controlling flow of IPA through different tanks.
On/ Off command is given to each Pump valve through PLC for operation of
the pump. Flow rate is to be controlled by varying the speed of the pump.
Analog output is to be given to drive the pump from the PLC. Chain diagram
and Pump control details to be finalized after detailed engineering. Pump
monitoring and control are required for Feed Pump and recirculation pump
only. Pump P1 shall be manually operated. List of pump is tabulated below.
Table: List of Pumps
Sl.no Pump Name
Fluid Medium
Type of Pump
1 Pump(P1) – manually
operated IPA Centrifugal
2 Feed pump(P2) IPA Centrifugal
3 Recirculation pump(P3) IPA Centrifugal
REQUIREMENTS FOR I/O QUANTITY FOR PUMP-MOTOR CONTROL
Feed Pump (P2)
Sl. No.
Parameters I/O Quantity Spare
1 Drive Ready FB DI 1
2
2 Drive Run FB DI 1
3 Drive OFF FB DI 1
4 Drive Trip FB DI 1
5 Speed Reference AO 1 1
6 Speed Feedback AI 1 1
7 Drive STOP Command DO 1
2 8 Drive Trip Command DO 1
9 Drive START Command DO 1
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Recirculation Pump (P3)
Sl.
No.
Parameters I/O Quantity Spare
1 Drive Ready FB DI 1
2 2 Drive Run FB DI 1
3 Drive OFF FB DI 1
4 Drive Trip FB DI 1
5 Speed Reference AO 1 1
6 Speed Feedback AI 1 1
7 Drive STOP Command DO 1
2 8 Drive Trip Command DO 1
9 Drive START Command DO 1
4A.5.3.3b.7 Powering of Equipments
The scope of work involves procurement, conduit laying and laying of cable
through conduits with one end termination in MCB and the other end
termination in instrumentation rack, console or other equipment.
For equipment powering, 230V, 50Hz power outlet is available in
instrumentation room at MCB distribution board.
This power from these MCB boards has to be distributed to equipment,
racks and consoles.
Main panel to Rack/console/equipment power distribution: The power
from MCB board is to be distributed to racks/consoles/equipment. The
power cable shall be laid in conduits and terminated in Terminal blocks/
sockets/ Master MCB on one side. The other end termination shall be
made in MCBs of MCB board.
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Rack power distribution: One master MCB shall be planned for
instrumentation rack for power distribution within rack equipment. From
Master MCB, power shall be distributed to other equipment of rack using
terminal blocks.
Console Power distribution: One master MCB shall be planned for 3
segments of console. From Master MCB, power shall be distributed to
other equipment of consoles using terminal blocks.
4A.5.3.3b.8 Grounding of Equipments
SCOPE:
The work involves cable shield preparation & and its wiring, laying of
grounding cable with one end termination in racks/ rack equipments and the
other end termination in grounding strip.
Separate instrumentation and power earth grounding strips are
available in the instrumentation room (Department scope).
The instrumentation earth and power earth are separately maintained.
The cable shields of all cables shall be prepared and terminated at all
termination points (Junction box/connector) in cleaning facility bay
except at sensor. The isolation from ground shall be ensured at all
termination points in cleaning facility bay.
In instrumentation rack, isolated instrumentation earth strip are
available. The instrumentation cable shields shall be connected to
earthing strip in rack and in turn to instrumentation earth strip
running through the building.
All the equipment body are to be connected to power earth.
4A.5.3.3b.9 Console - Equipment mounting and wiring
SCOPE:
The scope involves commissioning of consoles, equipment mounting and
its wiring. Also powering and grounding of all equipment shall be carried
out.
3 nos. of segmented console are planned for the facility.
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In these console, All in one PC (Personal Computers) will be placed for
data display/configuration/data processing/mimic display. These
consoles will be positioned in instrumentation room.
The switches, keys, indicators, power supply, keyboard for CCTV system
controller and intercommunication equipment shall be mounted in
consoles. Items like CCTV system controller and intercommunication
equipment will be in scope of Department. The consoles will be located
in instrumentation room.
4A.5.4 SITE ACCEPTANCE TEST (SAT) OF CONTROL SYSTEM.
After completion of commissioning of control system, SAT will be carried out.
The supply will be subjected to inspection and tests attended by Purchaser as
required. The Purchaser witness does not relieve the vendor from his
responsibilities for hardware, software, other accessories and services if
required.
Vendor shall submit installation, commissioning and acceptance
procedures (for hardware, the procedures shall include: purpose of test,
test definition, results expected and acceptance criteria).
Tests and acceptance of the system shall be carried out as per agreed
procedures and criteria based on specified guidelines and the vendor’s
standard procedures finalized during detailed engineering.
Client representatives are authorized to monitor supply completeness
and compliance to the requirements as per specification and schedule.
The supplier shall allow free access at any time to vendor works to
Purchaser’s representatives. The test details are briefed under control
system specifications section.
4A.5.5 TRAINING
a) The supplier shall provide adequate training to 3 Operational
Engineers at Department’s site after commissioning of the system for a
minimum period of 10 working days to maximum of 15 days.
b) The training shall be so organized to provide a complete
understanding of the functions of the system, overall system concepts
and routine operation for maintenance of the system and application
software development in control system by themselves. It is essential
that the system and other required document shall be available before
commencement of training.
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c) The details of training shall include
i. Hardware Installation
ii. System program development
iii. System Engineering & Configuration
iv. Networking / Communication technique
v. Installation of all software packages
vi. PID programming
vii. Data base creation & Management
viii. Mimic page creation and tag assignment
ix. Application program development in control system
x. Error diagnostics & trouble shooting
xi. Any other area on mutually agreed basis
xii. Hardware maintenance
4A.5.6 TESTING AND EVALUATION
The contractor shall bring all the required test and measure instruments
required for testing and evaluation. The standard Source/Measure equipments
with calibration validity traceable to national standards shall be used by the
contractor. The equipments of ±0.02% accuracy class of shall be used for
sourcing and measuring.
A. Testing and Evaluation
1. Only preliminary details regarding testing and evaluations are given
below. However the contractor shall prepare detailed Testing and
evaluation procedure and formats during detailed engineering phase. As
per the approved procedures, the contractor shall carry out the testing and
evaluation. The final results shall be entered in relevant formats and finally
to be approved by Department.
2. Check all the instruments for proper mounting and sealing. Check for
proper routing & harnessing of wiring. Ensure the availability of terminal
strip nos., Wire nos., tags and ferrules. Ensure proper grounding of
racks/equipments.
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3. Check and log insulation resistance of all cables, continuity of wiring of all
instrument loops as per the relevant drawings.
4. Integrity test up to sensor shall be done.
5. Power supply load test: All the power supplies shall be load tested up
110% of rated load. The stability and ripple test shall also be carried out.
Measurement system
6. A known input signal shall be fed from calibrated source/communicator
and the output shall be recorded in the control system. The results are to be
entered in a format. The format will be finalised at the time of detailed
engineering.
Command System
7. Coil resistance of SOV shall be measured.
8. Manual command shall be issued from control system and
the voltage at the SOV coil end in the case of E/P valve shall be measured.
9. E/P valve status shall be verified.
10. For pump control the speed variation shall be checked.
11. Status of pumps shall be checked.
12. Also in simulation mode, command acknowledgements shall be checked
in control system.
13. The results are to be entered in a format. The format will be finalised at
the time of detailed engineering.
B. Inspection & Quality Surveillance
14. The contractor shall prepare detailed inspection & quality surveillance
plan for all the items and services provided by the contractor.
15. All Instrumentation items supplied by the contractor (Annexure 3) and
services covered by this contract shall be subjected to inspection and
testing by department’s representatives.
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16. The inspection by the department’s representative and issue of inspection
certificate thereon shall in no way limit the liabilities and responsibilities
of the contractor in meeting the specification and quality requirements
specified.
17. The contractor shall supply the material test certificates / calibration
certificates (wherever mentioned) for the items under the supply of
contractor’s scope.
18. The contractor shall supply and maintain an independent comprehensive
database system containing inspection & testing and performance records
for each instrument.
5. EXECUTION SCHEDULE
The total contract period, reckoned from the date of award of the contract
to the date of commissioning and final acceptance of the system, shall be 10
months. The bidder shall indicate, in the bid, the schedules for various work
phases, which shall not exceed the overall contract period. Upon award of
contract and before commencement of work, the Contractor shall prepare a
detailed and comprehensive schedule for review and approval by the
Department. This approved schedule shall form the basis for all the works to be
performed by the Contractor.
The schedules shall be shown in the form of master PERT network and
show the date on which each part of the work is expected to begin and to be
finished. The Contractor shall prepare the detailed network charts for the total
contract period and it shall be up-dated once in a month. For each sub-system
or work package, an independent network chart is to be prepared. It is to be
noted that the schedule is the essence of the contract and Department will
closely monitor and take appropriate actions wherever necessary.
5.1. Project control and reporting
The Contractor shall establish a competent project management team with well-defined functional responsibilities. Close interaction with Department’s project team is essential at all phases of work. The following guide-lines indicate the requirements.
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5.2. Project reviews and meetings The preparation of all documentation for reviews and meetings is
the Contractor’s responsibility. The reviews shall be based on PERT/ CPM network schedules in each phase and shall be adhered to by the Contractor. The deviations, if any, are to be clearly documented and possible end effects brought out at each phase. The frequency of review at the closing phase of the project shall be suitably increased to resolve any outstanding issues.
5.3. Compensation for delay
If the Contractor fails to complete execution of the contract within the time specified in the contract or any extension thereof, the Department will recover from the Contractor as Liquidated Damages (LD) a sum of 0.5 % of the total contract price per week. The total liquidated damages shall not exceed 10 % of the contract price.
5.4. Cycle Time For Approval
The Department will communicate their disposition (approval,
rejection or comment) of the design & engineering documents, pre-
delivery inspection documents and Contractor’s proposal for
incorporation of additional Sub-contractor/ Sub-vendor within 7 working
days from the date of receipt, at the Department’s end, of such
documents, provided that the documents received are complete and in
compliance with the contractual obligations.
6. PHASES OF WORK
The overall scope of work is divided into 5 phases as follows:
Phase 1: Design review Phase 2: Detail engineering Phase 3: Fabrication Phase 4: Erection Phase 5: Commissioning
6.1. Design review
This phase shall commence immediately upon award of the contract. The design document, along with GA drawings and inter-face details of the equipments to be free-issued by the Department, shall be provided to the Contractor immediately upon award of the contract. The Contractor shall scrutinize the design and prepare their comments /recommendations in 1 month’s time. A joint design review meeting will be organised by the
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Department at Mahendragiri immediately on receipt of the Contractor’s comments/ recommendations. The design mutually agreed after the review shall be the basic document for execution.
6.2. Detail engineering
This phase shall commence immediately after the completion of the design review and ends with submission of the detail engineering documents by the Contractor to the Department and acceptance by the Department after review.
During this phase, the Contractor shall do the works listed in
Section 4.2.2/Volume-I, prepare the documents for the same and organize a joint Detail Engineering Review (DER) meeting at their office/ factory. The detail engineering phase of instrumentation system is provided in Section 4.A.1/Volume-I.
6.3. Fabrication
This phase shall commence upon approval and acceptance of the detail engineering documents by the Department. The detailed specification for fabrication is given in Section 2.1.,volume-II. This phase involves purchase of materials such as equipments, flow components, instruments, pipes, pipe fittings, etc, fabrication, testing, transportation to and unloading at the Department’s site. This phase shall also include in-plant training by the Contractor to the Department’s representative(s) on the fabrication of FSS. The in-process (stage) and pre-shipment (final) inspection of the system during fabrication shall be carried out by the TPI agency. Apart from inspection by TPI agency, the Department’s representative(s) may also carry out inspection at any stage at their own discretion. After completion of fabrication, but, prior to packing of the consignment for transportation, the Contractor shall organize a Pre-Shipment Review (PSR) at their office/ factory, in which the Contractor, the Department’s representative(s) and the TPI agency shall participate.
Upon approval by the Department, the Contractor shall pack and
transport the consignments to the Department’s site and un-load them at the site. The consignments shall be insured by the Contractor. The Contractor shall ensure minimum period of storage of consignments at the Department’s site. The consignments shall arrive at right phases so as to avoid both storage problems and delays. The Contractor shall undertake full responsibility of handling, transportation, insurance, clearance and storage.
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6.4. Erection
This phase shall commence upon un-loading of the consignments at the Department’s site. The detailed specification for erection is given in Section 2.2 volume-II The systems fabricated by the Contractor shall be stored in the Contractor’s temporary store at the site.
The mounting of equipments, joining of pipe-lines, testing, cleaning,
etc shall be carried out by the Contractor during this phase.
6.5. Commissioning
This phase shall commence upon completion of erection and the performance of the system is to be validated during this phase in compliance with the specifications of the contract. The detailed specification for commissioning is given in Section 2.3 volume-II . For instrumentation system, the scopes of works are explained in Section 4.A.2-5/VolumeI.
A final acceptance review will take place after all the necessary
commissioning trials are over and are documented as per the Department’s requirements. A training program on the systems and on each applicable sub-system shall be given at the end of the acceptance test to the Department’s representative(s).
7. WARRANTY
The performance of the system shall be guaranteed by the Contractor for
a period of 12 months from the date of final acceptance (after commissioning)
of the system at the Department’s site. The Contractor shall furnish a
Performance Bank Guarantee (PBG) for 10 % of the contract price for the
same.
7.1. System performance
The Contractor shall provide guaranteed performance of the system under the contract as per the specifications. The Contractor shall successfully demonstrate the performance during the commissioning. If the Contractor is unable to demonstrate the performance as per the specifications, within the stipulated period, and if the commissioning test results deviate from the specifications, the Contractor shall correct them at no extra cost for the Department and repeat the tests within a reasonable period of time as agreed to by the Department. The Contractor shall make effort practicable to correct the deficiencies. The Department
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reserves the option to reject the ill-performing equipments/ systems and when this option is exercised by the Department, the Contractor shall replace the rejected equipments/ systems by new ones at his own cost to the Department’s satisfaction within a reasonable period of time as indicated by the Department.
On the other hand, if the Department accepts the system, though it
fails to meet the specification fully, the Department will, at their own discretion, make necessary recoveries for such shortfall in performance.
In the event of rejection, in order to minimize the consequential losses, the faulty equipment shall be retained until a new replacement arrives at site for erection. It should be noted that as the faulty equipment has not been accepted and not taken over by the Department, the responsibility for it lies entirely with the Contractor. During this period, the Contractor shall not limit the use of faulty equipment except for reasons of safety during operation both for personnel and equipment.
7.2. Performance guarantee
The “Defect Liability Period” shall be 12 months from the date of final acceptance of the system to the satisfaction of the Department. The work shall not be considered as completed until the Department has certified in writing that they have been actually accepted and the Defect liability period shall commence from the date of such certificate. In case any defect in the work due to bad materials, and/ or bad workmanship develop in the work before the expiry of the period, the Contractor, on notification by the Department, shall rectify or remedy the defects at their own cost and shall make their own arrangements to provide materials, labour, equipment and any other appliances required in this regard. The equipments, or components repaired or replaced by the Contractor shall be guaranteed for a period of 12 months from the date of repairs or replacement.
The Contractor shall furnish performance guarantee in the form
of a bank guarantee from a nationalized/scheduled bank approved by
Reserve Bank of India(RBI), to the extent of 10 % of the total contract
value valid till expiry of warranty period & additional claim period of 6
months. If any defect is noticed by the Department during the defect
liability period and Contractor fails to rectify or remedy the defects, the
Department will have the right to get this done by other agencies and
recover the cost incurred, as determined by the Department, which shall
be final and binding, by recovery from the amounts due to the Contractor
and/ or by enforcing bank guarantee.
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8 GENERAL CONDITIONS
8.1. Entire agreement
8.1.1. The contract to be entered into shall convey the final agreement between the Department and the Contractor on the terms and conditions and be a complete and exclusive statement of the terms of the agreement.
8.1.2. In the event of conflicts between general conditions of contract and the
specification documents furnished by the Department, the latter will take precedence.
8.2. Modifications in the contract
This contract may be amended or modified only in writing signed by both the parties or their duly authorized agents or representatives by a change order issued by the Department and accepted by the Contractor, pursuant to the terms stated therein.
8.3. Cancellation of contract
8.3.1. The Department will have the right, at any time, to cancel the contract either wholly or in part by giving one month written notice. The Contractor shall undertake to observe the instructions of the Department as to the winding up of the contract both on his own part and on the part of his sub-contractors.
8.3.2. In the case of cancellation of the contract by the Department without
any fault of the Contractor, the Contractor shall forthwith take the necessary steps to implement the Department’s instructions. The period to be allowed to implement shall be fixed by the Department after consultation with Contractor and, in general, shall not exceed 3 months.
8.3.3. Subject to the Contractor conforming with the instructions referred to
in Section8.3.2,Volume I, the Department will take over from the Contractor at a fair and reasonable price all finished parts not yet delivered to the components and articles in course of fabrication in the possession of the Contractor for the performance of the contract, except such material. The Contractor shall, with the agreement of the Department, elect to retain.
8.3.4. The Department will, in no circumstances, be liable to pay any sum
which, when added to the other sums paid, due or becoming due to
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the Contractor under the contract and its amendments, if any, exceeds the total payment for the work set forth in the contract and its amendments, if any.
8.3.5. The ownership of all materials, part and unfinished work paid for by
the Department under the provisions of this Section shall be vested in or transferred to the Department as soon as they have been paid for.
8.4. Contractor’s default liability
8.4.1. The department shall reserve the right to terminate the contract in the circumstances detailed hereunder:
If the Contractor fails to rectify, re-construct or replace any defective
system/ sub-system/ equipment within a period of 30 days after the Department having given a notice to the Contractor to rectify, re-construct or replace the said defective system/ sub-system/ equipment or the Contractor delays, suspends or is unable to complete the system/ sub-system/ equipment by the date mutually agreed upon
If the Contractor commits breach of any of the terms and conditions of
the contract.
If the government of India decides to terminate the contract in public interest.
8.4.2. When the Contractor makes themselves liable for action under the
circumstances mentioned above, the Department will have power to forfeit the security deposit of the Contractor and the Contractor shall have no claim for damages whatsoever on such forfeiture.
8.4.3. The work remaining to be completed at the time of termination of the
contract shall be got executed through any other Contractor, in which case the expenses, which may by incurred in excess of sums, which would have been paid to the original Contractor, had the whole work been executed by them, shall be borne by the original Contractor and shall be recovered from them.
8.4.4. If this contract happens to be terminated as provided in Section
8.3.1/Volume-I, the Department, in addition to any other right provided in this article, may require the Contractor to transfer title and deliver to the Department in the manner and as directed by the Department
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a. any completed system/ sub-system / equipment
b. such partially completed system/ sub-system/ equipment,
drawings, information, which the Contractor specifically produced/ acquired for the performance of the contract.
The Department will pay to the Contractor as per the quoted prices in the contract for completed system/ sub-system/ equipment delivered to and accepted by the Department and for manufacturing materials delivered and accepted. For the partially completed system/ sub-systems/ equipment accepted by the Department, payment will be made at mutually agreed prices. After termination of the contract, the balance items of work shall be got executed by the Department through other agencies at the risk and cost of the Contractor.
8.5. Changes and modifications to specifications and qualitative
requirements 8.5.1. The Department shall reserve the right at any time to modify the
qualitative requirements, specifications, patents or drawings relating to the work covered by the contract. The Contractor shall inform the Department, within 30 days, of any objection they have to the modifications required.
8.5.2. The Department may also accept modification proposed by the
Contractor on his own initiative or on behalf of sub-contractors Or as a result of detail engineering review. 8.5.3. Unless the Department directs otherwise, the Contractor shall, in
either case, submit within a reasonable time limit to be specified by the Department, an estimate of the effect of any such modification in the cost of performance of the contract and/ or on the delivery schedule.
In the light of these estimates, the Department will decide whether and if so at what stage, the modifications are to be introduced and shall advise the Contractor in writing together with the Department’s new limits of liability.
8.5.4. When a modification or other change is so authorized, the Contractor
shall proceed with action in accordance with the Department’s direction. They shall moreover, as soon as possible after the receipt of such directions, submit to the Department a firm and detailed estimate showing any decrease or increase in cost entailed by the modifications and any effect its introduction will have on the delivery schedule.
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Any amendment to the contract which may be necessary in this respect
will be established within a reasonable time in the form of an amendment to contract, to be signed by both the parties. If the parties do not agree on the amendments to the contract, in particular regarding prices, responsibility, delivery schedule etc, the dispute shall be submitted to arbitration. 8.6. Sub-contracting
The Contractor shall not assign or sub-contract the work or any part of
the work without the written approval of the Department. In the event of
approval of sub-contractors, the detailed specifications and drawings of sub-
contracted items shall be approved by the Department.
All the works carried-out by such sub-contractors shall also be
scrutinized, inspected and approved by the Department. However, the
responsibility of the performance of such sub-contracted systems shall lie with
the Contractor. Any delay in carrying out the work by the sub-contractor which
affects the overall schedule of the work does not absolve the Contractor from
payment of compensation for the delays. All terms and conditions applicable to
the Contractor shall also be applicable to the sub-contractor who has been
assigned the sub-systems.
8.7. Compliance with standards
All the materials supplied or used shall be new and of first quality and manufactured and tested in accordance with the latest editions of the relevant Indian/ International standards. Wherever imported components are used, they shall be manufactured in accordance with the relevant standards published in the country of manufacture after allowing for specific aspects under Indian conditions such as tropical climate, etc. Any material or work, where no specific standard is applicable, shall be fabricated as per the instructions and directions of the Department.
All the electrical equipments used shall conform to the latest Indian
Electricity Rules as regards safety, earthing and other essential provisions specified therein for installation and operation of electrical parts.
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8.8. Secrecy The technical information, drawings, specifications and other related
documents forming part of enquiry or contract are the property of the Department and shall not be used for any other purpose, except for execution of the contract. All rights, including rights in the event of grant of a patent and registration of designs are reserved. The technical information, drawings, specifications, records and other documents shall not be copied, transcribed, traced or reproduced in any other form or otherwise in whole and/ or duplicated, modified, divulged and/ or disclosed to a third party and/ or not misused in any other form whatsoever without the Department’s consent in writing except to the extent required for the execution of this contract. These technical information, drawings, specifications and other related documents shall be returned to the Department with all approved copies and duplicates, if any, immediately after they have been used for the agreed purpose. 8.9. Inspection of work
8.9.1. The Department or any person appointed by it, shall have access and right to inspect the work, or any part thereof, at all times and places during the progress of the work. The inspection and supervision is for the purposes of assuring the Department that the plans and specifications are being properly executed and while the Department and its representatives will extend to the Contractor all desired assistance in interpreting the plans and specifications, such assistance shall not relieve the Contractor of any responsibility for the work. Any work which is proved faulty shall be corrected by the Contractor without delay. The fact that faulty work or work which is not in accordance with plan and specifications was not pointed out by the Department will not relieve the Contractor from correcting such work as directed by the Department without additional compensation.
8.9.2. The Department’s representatives shall at all reasonable times have free access to the works and/ or to the workshops, factories or other places where materials are being prepared or fabricated for the contract and also to any place where the materials are lying or from where they are being obtained, and the Contractor shall give every facility to the Department’s representatives for inspection and test of the materials and workmanship even to the extent of discontinuing portions of the work temporarily or of uncovering or taking down portions of finished work.
8.9.3. The Department has no obligation to discover defects patent or otherwise and it shall be the sole responsibility of the Contractor. The inspection and clearance for dispatch by Department’s representatives shall not absolve the Contractor’s obligations and duties under terms and conditions herein.
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8.10. Co-ordination with other contractors and inter-facing of the works
The Contractor shall extend all co-operations to other contractors of the Department to perform their works at site simultaneously. The Contractor shall so arrange their schedule of activities as to ensure smooth and timely execution of the project, minimize interference with the works of the other contractors and allow the other contractors the use of the facilities put up by them for erection activities. For this purpose, the Contractor shall plan such works and indicate such inter-faces in an inter-face schedule. They shall not be entitled to any extra payment on this account. The Department will not entertain any claim from the Contractor for delay on account of lack of co-ordination with the other contractors. 8.11. Force majeure
If at any time during the currency of the contract, the performance in whole or in part by either party of any obligation under the contract is prevented or delayed by reasons of any war, hostility, acts of the public enemy, civil commotion, sabotage, fire, floods, epidemics, quarantine restrictions, strikes, lock-outs or acts of God (hereinafter referred to as Eventualities) and if notice is given by either party to the other within 21 days from the date of occurrence thereof, neither party shall for reasons of such eventuality be entitled to terminate the contract nor shall either party have any claim for damages against the other in respect of such non-performance or delay in performance. The performance under the contract shall be resumed as soon as practicable after such eventualities have come to an end and the decision of the Department whether the performance has been resumed or not shall be final and conclusive.
Provided further that if the performance in whole or in part of any
obligation under the contract is prevented or delayed by reasons of any such eventuality for a period exceeding 60 days, the Department may at the option terminate the contract provided also that if the contract is terminated under this clause, the Department will be at liberty to take over from the Contractor at a price to be fixed by the Department which shall be final, all unused, un-damaged and acceptable materials, bought-out components and stores in course of erection and commissioning in the possession of the Contractor at the time of such termination of such portion thereof as the Department may deem fit excepting such material, bought-out components and stores as the Contractor may with the concurrence of the Department elect to retain.
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8.12. Indemnify to department against infringement of labour laws
The Contractor shall indemnify the Department against any action, claim or proceedings relating to infringement of all or any of the prevailing labour laws of India like Workmen’s Compensation Act 1923, Contract Labour (Regulation and Abolition) Central Rules 1971, Employees Liability Act 1938, Industrial Disputes Act 1947, Employees Provident Funds and Miscellaneous Act 1952 during erection and commissioning at site.
8.13. Patent rights
The Contractor shall fully indemnify the Department against any action, claim or proceedings relating to infringements or use of any patent or design or any alleged patent or design rights and shall pay any royalty which may be payable in respect of any claims made under or any action brought against the Department. In respect of such matters as aforesaid, the Contractor shall be set at liberty, at their own expense, to settle any dispute or to conduct any litigation that may arise there-from. The Contractor shall not be liable to indemnify the Department on the infringement of the patent or design or any alleged patent or design right which is the direct result of an order passed by the Department. 8.14. Arbitration
The Parties shall carry out their respective obligations under the Contract
in the spirit of mutual cooperation, good faith & harmony. Except in matters in
respect of which the decision of the Department is final as specified in the
Contract, any difference, dispute or controversy shall be resolved and settled
amicably among the Parties through mutual consultations. If, however, that is
not possible, the Parties shall agree that all disputes arising out of or in
connection with the Contract shall be finally and conclusively decided by
arbitration and the award in pursuance thereof shall be binding on the Parties.
The court of arbitration shall base its decision on this Contract with resort to Indian law. The arbitration shall take place in India. The language shall be English. Work under the Contract shall, if reasonably possible, continue during arbitration proceedings.
a. In the event of any question, dispute or difference arising under these
conditions or any condition contained in the Contract (except as to any
matter the decision of which is specially provided for by these
conditions), the same shall be referred to the sole arbitration of the
Director, IPRC or some other person appointed by him. There shall not
be any objection that the arbitrator is a Government servant; that he had
to deal with matter to which the Contract relates; or that in the course of
his duties as Government servant he has expressed views on all or any
other matters in dispute or difference. The award of the arbitrator shall
be final and binding on the Parties to the Contract.
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If the arbitrator be the Director, IPRC,
i. In the event of his being transferred or vacating his office by
resignation or otherwise, it shall be lawful for his successor-in-
office either to proceed with reference himself or to appoint
another person as arbitrator or
ii. In the event of his being unwilling or unable to act for any
reason, it shall be lawful for the Director, IPRC to appoint
another person as arbitrator.
If the arbitrator be a person appointed by the Director, IPRC, in the
event of his dying, neglecting or refusing to act or resigning or
being unable to act, for any reason, it shall be lawful for the
Director, IPRC either to proceed with the reference himself or
appoint another person as arbitrator in place of the outgoing
arbitrator.
Subject as aforesaid, the Arbitration & Conciliation Act 1996 and
the rules there under and any statutory modification thereof for the
time being in force shall be deemed to apply to the arbitration
proceedings under this Section. The Arbitrator shall have the
power to extend, with the consent of the Department and the
Contractor, the time for making and publishing the award. The
venue of arbitration shall be the place as Department in their
absolute discretion may determine. Work under the Contract shall,
if reasonably possible, continue during arbitration proceedings.
b. In the event of any dispute or difference relating to the interpretation
and application for the provisions of the Contract, such dispute or
difference shall be referred by either Party to Arbitration of one of the
Arbitrators in the Department of Public Enterprises. The Arbitration Act
1996 shall not be applicable to arbitration under this clause. The award
of the Arbitrator shall be binding upon the Parties to the dispute,
provided, however, any Party aggrieved by such award may make a
further reference for setting aside or revision of the award to the Law
Secretary, Department of Legal Affairs, Ministry of Law & Justice,
Government of India. The Parties to the dispute will share equally the
cost of arbitration as intimated by Arbitrator.
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8.15. Assignment
The contract shall be binding upon the successors and assignees of the parties hereto. It shall not be assigned in whole or in part by either party without prior written consent of the other. If the Contractor becomes insolvent or being a firm or company whether incorporated or not is dissolved or goes into bankruptcy or is caused to be wound up except for re-construction purposes or carried on its business under a receiver, the representatives in law of the estate of the Contractor or any such receiver, liquidator or any person in whom the agreement may be vested shall forthwith give notice thereof in writing to the Department and shall remain liable for the successful performance of the Contractor or the successors of their obligations under this contract under any circumstances. 8.16. Jurisdiction and applicable law
The contract shall be governed by the laws of India in force. The courts of the state only shall have jurisdiction to deal with and decide any legal matters or dispute whatsoever arising out of the contract. 8.17. Execution of work
The specifications of the contract are intended to describe and provide for
a finished system. It is to be understood and agreed by the Contractor that the work described shall be complete in every detail, even though every item necessarily involved is not particularly mentioned. The Contractor shall be required to provide all labour, materials and equipment necessary for the entire completion of the work described and shall not avail themselves of any manifesting unintentional error, omission or inconsistency that may exist. The Contractor shall carry out and complete the work in every respect in accordance with the contract and the directions and to the satisfaction of the Department.
8.18. Rights of the department 8.18.1. Right to illustrate and explain plans a. The various parts of the contract are intended to be complementary to each
other but should any discrepancy appear or any mis-understanding arise, the explanation of the Department will be final and binding.
b. The correction of any errors or omissions of specifications may be made by
the Department, when such correction is necessary to bring out clearly the intention which is indicated by a reasonable interpretation of the specifications as a whole.
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c. Wherever in the specifications which are a part of the contract or which
may be furnished to the Contractor for directing the work, the terms and descriptions of various qualities of workmanship, materials, structures, processes, plant or other features of the contract are described in general terms, the meaning or fulfillment of which must depend upon individual judgments, then in all such cases, the question of shall be decided by the Department and said material shall be furnished, said work shall be done, and said structure or feature shall be constructed, furnished or carried out in full and in accordance with their interpretation of the same and to their full satisfaction and approval, provided such interpretation is not in direct conflict with the specifications or generally accepted good practice.
8.18.2. Right to direct work
a. The Department will have the right to direct the manner in which all work under this contract shall be done, in so far as it may be necessary to secure the safe and proper progress and the specified quality of the work and all work shall be done and all material shall be furnished to the satisfaction and approval of the Department.
b. Whenever, in the opinion of the Department, the Contractor has made
marked departures from the schedule of completion laid down in the contract or when untoward circumstances force departure from the said schedule, the Department, in order to assure compliance with the schedule and the provisions of the contract, shall direct the order, pace and method of doing the work, which shall be adhered to by the Contractor.
c. If, in the judgment of the Department, it becomes necessary at any time to
accelerate the overall execution of work, the Contractor when ordered and directed by the Department will cease work at any particular point and transfer their men to such other point or points and execute such portion of their works, as may be required, to enable others to hasten and properly engage and carry on their work, as directed by the Department.
d. The work by the Contractor at site beyond normal working hours (08:45 to
17:15 hr) on working days and any time on holidays (including Saturdays and Sundays) shall be permitted only with prior approval of the Department. The Department may also direct the Contractor to operate extra shifts over and above normal day shift to ensure completion of the contract on schedule if, in the opinion of the Department, such work is required.
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8.18.3. Right to order modifications of methods and equipment
If at any time the Contractor’s methods, materials or equipments appear to the Department to be unsafe, inefficient or inadequate for securing the safety of the workmen or the public, the quality of work or the rate of progress required, the Department may order the Contractor to ensure their safety and increase the efficiency and adequacy and the Contractor shall promptly comply with such orders. If at any time the Contractor’s work-force and equipment are in the opinion of the Department, inadequate for securing the necessary progress, as herein stipulated, the Contractor shall, if so directed, increase the work-force and equipment to such an extent as to give reasonable assurance of compliance with the schedule of completion. The absence of such demands from the Department will not relieve the Contractor of their obligations to secure the quality, the safe conducting of the work and the rate of progress required by the contract and the Contractor alone shall be and remain liable and responsible for the safety, efficiency and adequacy of their methods, materials, work-force and equipment, irrespective of whether or not they make any change as a result of any order or orders received from the Department. 8.19. Contractor’s functions 8.19.1. The Contractor shall provide everything necessary for the proper
execution of the work according to the intent and meaning of the specifications whether the same may or may not be particularly shown or described therein, provided that the same can reasonably be inferred there-from and if the Contractor finds any discrepancy there-in, they shall immediately and in writing refer the same to the Department whose decision shall be final and binding on the Contractor.
8.19.2. If any part of the Contractor’s work depends for proper execution
upon the work of any other contractor, the Contractor shall inspect and promptly report in writing the Department any defect in such work of the other contractors that tender it un-suitable for proper execution of the work under this contract. Their failure to so inspect and report shall constitute acceptance of the other contractor’s work as fit and proper for the reception of their work, except as to defects which may develop in the work of the other contractors after proper execution of the work. To ensure proper execution of their subsequent work, the Contractor shall measure the work already in place and shall at once report to the Department any discrepancy between the executed work and the drawings.
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8.19.3. The Contractor shall not sell, assign, mortgage, hypothecate or remove equipments or materials which have been erected or which may be necessary for the completion of the contract without the written consent of the Department.
8.19.4. In the execution of the work, no person other than the Contractor, or
their duly appointed representatives, their sub-contractors and their workmen, shall be allowed to do work at the site except by the special permission, in writing by the Department.
8.19.5. The Contractor shall proceed with the work to be performed under
this contract and each and every part and detail thereof, in the best and most workmen-like manner by engaging qualified, careful and efficient workers and do the several parts thereof at such time and in such order as the Department directs and finish such work in strict conformance with the plans, drawings and/ or specifications, and any changes, modifications or amplifications thereof made by the Department.
8.19.6. In respect of observance of local rules, administrative orders, working
hours and the like, the Contractor and their personnel shall co-operate with the Department.
8.20. Supply of tools, tackles and other materials 8.20.1. For full completion of the work, the Contractor shall, at their own
expense, furnish all necessary false work, erection tools, machine tools, power tools, tackles, hoists, cranes, derricks, cables, slings, skids, scaffolding, work benches, tools for rigging, cribbing and blocking, welding machines, pre-heating and stress relieving equipment, X-ray and all associated protective equipments, appliances, materials and supplies required to accomplish the work under the contract unless otherwise provided for. Adequacy of such tools shall be subject to final determination of the Department.
8.20.2. The Contractor shall also furnish all necessary expendable devices like
anchors, grinding and abrasive wheels, plugs, hacksaw blades, taps, dies, drills, reamers, chisels, files, carborundum stones, oil stones, wire brushes, necessary scaffolding, ladders, wooden planks, timbers, sleepers, and consumable materials like oxygen, acetylene, argon, lubricating oils, greases, cleaning fluids, cylinder oil, graphite powder and flakes, fasteners, gaskets, temporary supports, stainless steel shims or various thicknesses as required, cotton waste, PTFE tapes and all other miscellaneous supplies of every kind required for carrying out the work under the contract.
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8.20.3. The Contractor shall provide all reasonable facilities including tools,
personnel, etc and ensure co-ordination with the Department and their inspection agencies so as to enable them to carry out all supervision, measurements, checks, etc in a satisfactory manner.
8.20.4. The Contractor shall not dispose, transport or withdraw any tools,
tackles, equipments and materials provided by them for the contract without taking prior written approval from the Department and the Department at all times shall have right to refuse permission for disposal, transport or withdrawal of tools, tackles, equipment and material if in their opinion, the same will adversely affect the efficient and expeditious completion of the work.
8.21. Protection of work 8.21.1. The Department will not be responsible or held liable for any damage
to person or property consequent upon the use, misuse or failure of any construction/ fabrication tools and equipment used by the Contractor or any of their sub-contractor’s, even though such construction tools and equipment may be furnished, rented or loaned to the Contractor or any of their sub-contractor. The acceptance and/ or use of any such construction tools and equipment by the Contractor or their sub-contractors shall be construed to mean that Contractor accepts all responsibilities for and agree to indemnify and save harmless the Department from any and all claims for said damages resulting from said use, misuse or failure of such construction tools and equipment.
8.21.2. The Contractor and their sub-contractors shall be responsible during
work for protection of the work which has been completed by the other contractors. The necessary care shall be taken to see that no damage to the same is caused by their own men during the course of execution of their work.
8.21.3. All other work completed or in progress as well as machinery and
equipment that are liable to be damaged by Contractor’s work shall be protected by the Contractor and such protection shall remain and be maintained until its removal is directed by the Department.
8.21.4. The Contractor shall effectively protect all the works from action of
weather and from damages or defacement and shall cover finished parts where required for their thorough protection.
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8.21.5. The Contractor shall cover the work by a Contractor’s all-risk policy during the currency of the contract.
8.22. Site Personnel
The Contractor shall identify a Manager and who shall be personally present or employ his/ her representatives whose names shall have previously been communicated in writing to the Department and approved by the Department to supervise the work under the contract. The Manager shall have full technical capability and complete administrative and financial powers to expeditiously and efficiently execute the work under the contract. Any written orders or instructions which the Department may give to the Contractor’s Manager or his/ her representatives shall be deemed to have been given to the Contractor.
The Contractor’s Manager shall maintain an office on or adjacent to the
site of work and shall at all times keep in the said office a complete set of the specifications and drawings. The Department will normally communicate directly with the Contractor’s Manager at site. In the event of a partnership firm, then, this paragraph shall be interpreted to mean the attention of an Officer of the Company or Corporation or members of the partnership firm.
8.23 First Aid
The contractor may have access to the Departments qualified first aid
personnel and ambulance in case of accidents, subject to the availability of the
same. However, the Contractor shall make his own medical and transport
arrangements to take care of his employees in case of accident. The Contractor
shall provide a first aid kit at the work site to meet the requirements of minor
injuries.
8.24 Reporting
The Contractor must report the following information to the Department
by the end of every week during the work at Department’s site.
a. Progress achieved
b. Expected dates for completion of individual works
c. Any actual or likely delay in the execution of work
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8.25 Working and Safety Regulations
The Contractor shall observe all statutory and legal requirements
enforced by Central and State Government applicable to the work as well as any
local regulations applying to the site issued by Department or any other
authority. Particular attention is drawn to the following;
a. In case of accident, the Department shall be informed in writing
forthwith. The Contractor shall strictly follow the regulations laid down
by the Factory Inspector, Central and State Government authorities in this
regard.
b. Compliance with all electricity regulations.
8.26 Electrical Safety Regulations
In no circumstance will the Contractor interfere with fuses and electrical
equipment belonging to the Department or other Contractors. Before the
Contractor connects any electrical appliance to any plug or socket belonging to
other Contractor or Department, he will
a. Satisfy the Department that the appliances are in good working condition
b. Inform the Department about the maximum current rating, voltage and
phase of the appliance
c. Obtain permission of the Department detailing the sockets, to which the
appliance may be connected.
8.27 . Power
Electricity will be supplied as mentioned in Sl. 4.1.5/Volume-I.
Contractor must provide power supply distributor with isolator for taking
power for his equipments. Contractor should obtain Electrical safety clearance
from both CMG group and safety clearance from safety division of IPRC before
starting the work.
8.28. Water
Free supply of water will be made available by the Department.
8.29. Power, office, tool room, stores, etc
The Department will provide at a fixed point near the work spot of the Contractor electrical power free of cost. It shall however be the responsibility of the Contractor to extend the facility to suit their requirement at their own cost.
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The Contractor shall not however have any claim against the Department
in the event of failure, interruption/ insufficiency of these services. If required, the Contractor may employ a portable Diesel Generator (DG) set to get regular power supply. The Department will provide at site, free of cost, space for construction of an office and of a room for proper storage of instruments and precision tools. However, the office, the room for storing instruments, precision tools, etc and other constructions such as tool room adjacent to place of installation, welding sheds, fabrication sheds, labour rest rooms, etc, shall be installed by the Contractor at their own cost, only at locations designated and only if approved by the Department. 8.30. Clean-up of work site
The Contractor shall not store or place the equipment, materials or erection equipment on the drive ways and streets and shall take care that their work in no way restricts or impedes traffic or passage of men and material. During erection, the Contractor shall without any additional payment, at all times keep the working and storage area used by him free from accumulation of loose or combustible material, waste materials or rubbish to avoid fire hazard and hindrance to other works of the Department. If the Contractor fails to comply with these requirements, the Department will proceed to clear those areas and the expenses incurred by the Department in this regard shall be payable by the Contractor. Before completion of the work, the Contractor shall remove or dispose in a satisfactory manner all scaffolding, temporary structures, sheds, buildings, stores, waste and debris and leave the premises in a condition satisfactory to the Department.
8.31 Safety and Reliability
Since the systems are highly complex in nature, the philosophy and
criteria to be adopted shall be highly safety-and-reliability-oriented for their
systematic and proper functioning. The designs of the sub-system, components,
equipments to be carried out by the Contractor shall specifically address
essential safety provisions both in-built and external. Reliability is a prime
factor, which has to be embedded in the process of realization of the system. To
ensure that the sub-system design, development, selection of equipment,
components, material, etc are in compliance with the standard engineering
practices, it is necessary to follow established design codes and standards.
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8.32 Security Deposit
The Contractor including MSEs and Start-ups shall deposit an interest
free amount equivalent to the 10 % of the total order value towards Security
Deposit for the due performance of the Purchase Order within 30 days from the
date of Purchase Order. Central PSUs/PSEs/Autonomous bodies shall be
exempted from the payment of security deposit , and instead, an indemnity
Bond shall be secured from them in lieu of the Security deposit. The security
Deposit can be submitted either in the form of (a) Cash to the Accounts Officer,
IPRC against proper Receipt, (b) Demand Draft drawn in favour of Accounts
Officer, IPRC, (c) Bank Guarantee in Rs.100/- Non-judicial Stamp Paper
obtained from any Nationalized/Scheduled Bank and (d) Tern Deposit Receipts
duly endorsed by the respective Banks in favour of Accounts Officer, IPRC.
This security deposit shall be returned to the Supplier only upon successful
completion of all the contractual obligations or shall be adjusted/forfeited
against non-fulfilment of any of the contractual obligations.
8.33 Quality Assurance
The reliability of Instrumentation is a combination of specification of the
equipments/components, serviceability and maintenance of the same, which are
meant to serve and provide effective and timely operation, which includes
trouble- free performance of systems and sub-systems to the intended
specifications.
The Contractor must look for the quality factors individually attributed to
engineering developments, redundancy philosophy adopted, selection of
equipments and components, test and acceptance procedures followed,
repetitive performance achieved, risk analysis carried out, etc. each and every
module must be manufactured and tested to international Quality Control
standards. The test certificated shall be provided to Department.
The quality assurance is an unified approach that attempts to control the
quality right from design stage to commissioning stage, which includes the
checking of the adequacy of the equipments/ components for materials,
fabrication, installation, testing. It is the combined responsibility of the
Contractor and the Department to ensure that all possible failure modes are
exercised and validated during FAT.
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8.34 Purchase of Materials
The selection of equipments, components, materials, etc. with appropriate
and suitable specifications shall be the responsibility of the Contractor, as
overall performance of the system rests with the Contractor. Accordingly, the
selection and purchase tasks shall be handled by the Contractor immediately
after the approval of Detailed Engineering documents by the Department.
The criteria for selection of particular product and the reasoning involved
therein shall be submitted to the Department for necessary approval. However
Department’s decision will be final.
The Department will provide necessary end-use certificate for obtaining
the required license for import of items if required by the Contractor.
In keeping with the terms of the Contract, the Contractor shall undertake
the responsibility for handling, packaging and transportation involved to the
accepted level of any sub-systems/ equipment covered by the work in the
Contract.
8.35 Employment of Labours
The Contractor shall deploy Indian National only for execution of the
work.
Only skilled employees with experience of this particular work shall be
employed.
No person below the age of 18 years shall be employed.
The Supplier shall pay to each person, wages not less than those specified
by Minimum Wages Act.
The employees/labour, for carrying out all the site works shall be
identified well in advance by the Contractor and necessary approval shall
be obtained from the Department for entry permit to the work site.
8.36 Gate Pass
For Contractor’s equipment, tools, materials, etc. which are to be taken out from IPRC, Mahendragiri campus after completion of work, proper entry shall be made at the main gate duly endorsed by CISF. The Department shall issue necessary gate passes for taking out the Contractor’s materials, as and when required and after completion of work
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8.37 Facilities to the department
During the currency of the contract, the Department may have its authorized representative(s) stationed at the factory of the Contractor. The Contractor shall provide office accommodation for the Department’s representative(s) and also to permit the usage of telephone, fax, E-mail, etc, as and when found necessary.
9 INSTRUCTION TO BIDDER
The proposals are invited on behalf of the President of India by the Head,
Purchase & Stores, IPRC, Mahendragiri, from the Bidders for the work
described in this RFP document for IPRC, Mahendragiri. The bids shall be
submitted online through IPRC centre e-link.
9.1 Scope of work: The scope of the work is establishment of Fluid
Servicing system through Engineering, Procurement & Construction
(EPC) mode as per the specification given in this document. The
Contractor is required to submit a complete bid for the entire work
mentioned herein. Any incomplete bid will be summarily rejected.
9.2 Execution period: The entire work is to be completed within
10 months. The Contractor shall submit a master schedule detailing their
realization plan so as to comply with the overall execution period stated
herein, in the form of a Gantt chart, indicating the sequence and duration
of the various phases of work.
9.2.1 Validity: The bid submitted shall be valid for a period of 8 months
from the due date for opening of the techno-commercial bid.
9.2.2 The Department reserves the right to reject any or all bids in whole
or part without assigning reason thereof.
9.3 Form of bid: The bid shall be submitted in 2 separate parts viz Part 1 for
Techno-commercial bid and Part 2 for Price bid.
9.3.1 Techno-commercial Bid: The techno-commercial bid shall give the
complete details on technical & commercial aspects only. The techno-
commercial bid shall not contain any price detail. Mention of any price
detail in the techno-commercial bid will render the entire bid invalid.
The techno-commercial bid may include a format of the price bid by the
Contractor, without any detail of the price quoted. Deviation, if any, in
the Contractor’s proposal with respect to this document shall be explicitly
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mentioned in the schedule of deviations to be provided in the bid. If the
Contractor does not mention any deviation, it shall be construed by the
Department that the Contractor agrees to comply with each and every
aspect of this document.
9.3.2 Price bid: The price details shall be mentioned only in the price-bid
template in e-Procurement portal.
9.3.2.1 Any additional price detail may be attached as a pdf.
document (signed & scanned) to price bid only. Mentioning
any form of price in the techno commercial part will result in
summary rejection of the bid submitted by the particular
bidder.
9.4 Online Bid Submission
The instructions to the Bidders for online submission of their proposals
through IPRC centre e-Procurement link are as follows:
9.4.1 The Bidders shall arrange all resources, including Digital Signature
Certificates (DSC) and Internet connections, at their own cost for
participating in online bidding. The bid shall be submitted online in the
IPRC Centre link before the due date and time as specified in the tender
schedule in the portal.
9.4.2 All enquiries regarding the tenders and submission of offers shall be
online and only through our e-Procurement portal.
9.4.3 The Bidder may approach helpdesk on the home page for any technical
help (e-mail: [email protected] and Phone: 0091 20 2531555)
9.4.4 In case the Bidder encounters any technical snag pertaining to e-
Procurement system while acting on the tender, computer screenshot of
the error message with date & time stamp on the web-browser along with
the query shall be emailed by the Bidder to the help desk (as mentioned
above) for problem resolution at least 24 hours before the due date and
time of the bid submission.
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9.4.5 The time taken to ascertain, evaluate and suggest a solution for the
problem reported by the Bidder may vary from case to case. Hence, the
Bidders are advised to submit the bid well in advance before closing date
and time to avoid last-minute issues.
9.4.6 The Department will not be responsible for failure of the Bidders in
submitting bids online caused due to technical reasons at the Bidder’s end
such as network or power failures, computer failure, internet browser,
mistakes/ errors in filling the bids online, etc.
9.4.7 Queries by the Bidders on technical problems on the last day of bid
submission will not be binding on the Department for resolving/
addressing. The Department will not be responsible for non-submission
of bids in those cases.
9.4.8 The Server Date & Time as appearing on our website
(https://eprocure.isro.gov.in) shall only be considered for the cut-off date
and time for receipt of bids.
9.4.9 Request, if any, for extension of tender due date shall reach the
Department at least 4 working days in advance of due date and time for
consideration. The Department is not bound by such requests to extend
the due date unless it feels necessary.
9.4.10 The e-procurement system does not permit submission of any bid after
closing date and time of the e-tender. Hence, there is no scope for any
late or delayed bid in the online process.
9.4.11 Requests for extension of due date and time citing technical issues in
online submission of bids will not be entertained.
9.4.12 In case there is complete breakdown of e-Procurement system on the last
day of the tender for any reason, then the Department may extend the
date for submission after their own assessment.
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9.4.13 The Bidders have to note that once rework is initiated, the status of the
earlier submitted bid becomes pending till the bidding process is
completed once again. During the process of rework, bid data submitted
earlier becomes invalid and will not be available for opening. If rework is
initiated, then Contractor has to complete the entire process of bid
submission once again within the due date and time for a valid bid
submission.
9.4.14 The Department will not be responsible for non-submission of bids
resulting due to failure of the Bidder to once again complete the process
of bid submission before due date after reworking of the submitted bid is
initiated.
9.4.15 Any unsolicited clarification/ change/ modification sought by the
Bidders after submitting their bids will not be considered.
9.4.16 The Bidders shall note that since this is a two-part bid, the price details
shall be mentioned only in the price-bid template. If the price
details either in part or full are indicated in the technical bid, the
bid will be disqualified.
9.4.17 The Bidders may note that, in e-procurement system, submission of bid is
a 2-step process. After submission of their bids, the Bidders have to wait
for bid sealing by the Department. Following that, the Bidders have to
submit open authorization in the e-procurement system to enable the
Department to open the bid. If open authorization is not completed by the
Contractor, then the Department will not be able to open the bid and the
bid becomes invalid.
9.4.18 The Bidders may note that digital keys of Class III USB tokens, which
support both digital signing and encryption are to be used for bidding in
IPRC e-procurement system
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9.4.19 The Bidders may note that they have to use the same digital key
with which they submitted the bid to give open authorization. If
the Bidders use different key for open authorization, the system will not
accept the open authorization and the bid becomes invalid.
9.4.20 In case the digital key which is used during bid submission expires before
giving open authorization, then the Bidder has to first login with the new
key and use the expired key for completing open authorization process
for the bid.
9.4.21 The Bidders may note that the maximum file size that can be uploaded
per attachment in e-procurement system is 4 MB (in pdf format). If the
document is more than 4 MB, then the document is to be split into
multiple documents of size less than 4 MB and uploaded into
attachments. Literature/ Technical data should accompany the bid.
9.4.22 Similarly, if the number of files to be uploaded is more than the number
of attachments allowed in the bid, then the files are to be grouped into
folders such that the number of folders is less than the number of
attachments. Further, the folders may be compressed using zip/ archive
format and uploaded as attachments. However, the attachment size
should still be less than 4 MB.
9.4.23 The Bidders may note that documents including literature/ technical data
are to be uploaded through e-procurement system only.
9.4.24 Bids sent through post, telegram, fax, telex, e-mail, courier, etc will not be
considered. Partially completed/ incomplete bids will not be considered.
9.5 Liquidated Damages
Deliver & Commissioning is the essence of this contract. If the Contractor
fails to meet delivery specified in the contract or any extension thereof, the
Department will recover from the Contractor as Liquidated Damages (LD) a
sum of 0.5% of the total contract value for each calendar week of delay or part
thereof. The total liquidated damages shall not exceed 10 % of the contract
value.
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9.6 Delivery Term
For all the items regarding the establishment of Automated Continuous
Cleaning Facility the delivery point is at IPRC Mahendragiri.
9.7 Languages and Measures
All documents pertaining to the Contract including specifications,
schedules, notices, correspondence, operating and maintenance instructions,
drawings or any other writings shall be written in ENGLISH language only.
9.8 Documents
All operating, maintenance and technical manuals, drawings and
diagrams in English Language relevant to the system/components shall be
supplied by the Contractor.
On the other hand, if the Department accepts the system, though it fails to
meet the specification fully, the Department will, at their own discretion, make
necessary recoveries for such shortfall in performance.
In the event of rejection, in order to minimize the consequential losses,
faulty equipment shall be retained until a new replacement arrives at site for
installation. It should be noted that the faulty equipment has not been accepted
and not taken over by the Department, the responsibility for it lies entirely with
the Contractor. During this period, the Contractor shall not limit the use of
faulty equipment except for reasons of safety during operation both for
personnel and equipment.
9.9 Prices
The bidder shall quote firm and fixed prices valid during the currency of
the contract till commissioning and final acceptance of the test stand to the
satisfaction of the Department. The prices shall include all taxes, levies like
octroi, duties, taxes, royalties, permits charges, etc, levied by any central, state,
local or other Governmental authority, which the Contractor is required to pay
in their country as well as in India with reference to the fabrication, purchase,
transportation up to the delivery point stated in this document.
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The bidder shall provide the minimum level of break-up prices as given
in the Table. A in PRICE DETAILS . However, the bidder is advised to quote
the item-wise break-up prices of the various items forming the sub-systems, to
such fine extent as necessary and possible.
The price of the materials purchased from the sub-contractors and the
services rendered by the sub-contractors in India shall be separately mentioned
in the bid, for which the payment shall be made in Indian currency only.
There shall not be any change in the contract price due to addition/
deletion and reduction/ increase in the sizes of fluid circuits arising out of the
design review and detail engineering review.
9.10 Taxes and Duties
9.10.1 IPRC is eligible for concessional GST @ 5% for supply portion and
@ 18% for service portion against notification no. 47/2017 and
45/2017. Necessary exemption certificate shall be provided as and
when required against invoice.
9.10.2 The Bidder shall indicate, separately in the price bid, the applicable
rate of Goods and Service Tax (GST) and Custom Duty levied by
the Central or State Governments within India for materials or
services prevailing at the time of submission of bid. In case of any
change in rate or structure of taxes, duties or levies by the Central
or State Governments within India, the taxes shall be reimbursed at
actual.
9.10.3 The Department is eligible for concessional rates of GST for supply
of materials as per Notification # 45/2017- Central Tax and
47/2017-Integrated Tax dated 14/11/2017.
9.10.4 The Department is eligible for concessional rates of Custom Duty
as per Notification # 5/2018 dated 25/01/2018 for imported
materials and also the materials manufactured in Special Economic
Zones in India exclusively to be utilized for this CTPT project of
IPRC against proforma invoice submitted by the Foreign
Contractor/ Sub-vendor.
9.10.5 The Department will make statutory deduction on account of
Income tax as per the extant provisions of the Indian Income Tax
Act, 1961 and issue “Tax Deducted at Source (TDS)” certificate to
the Indian Contractor.
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9.11 Quantity Variation
Unit prices specified in contract for all the items shall remain valid as
long as actual quantity installed is within ± 25% of the total quantity specified in RFP.
For variation above ± 25%, due to any change in scope of work, a Joint Review Board including /Contractor’s representatives shall be constituted to arrive at the price on mutual agreement without holding the work.
Payment shall be made as per the actual quantity consigned to IPRC Mahendragiri. However, the quantity to be ordered shall be mutually agreed during Detail Engineering. 9.12 Payment Terms
9.12.1 Advance Payment
The Department does not normally entertain advance payment.
However, in case the Bidder proposes for advance payment, the Department
may consider it, subject to the following conditions:
a. Bank Guarantee for equivalent sum from a nationalized/ scheduled
bank approved by RBI or a reputed first-class international bank
valid till final acceptance of Fluid servicing system of Automated
Continuous Cleaning with additional claim period of 6 months is to
be submitted.
b. In case of different advance payment terms proposed by the Bidders,
the Department will load simple interest on the advance payment
over the execution period in accordance with MCLR as notified by
State Bank of India applicable on the due date for submission of bid
for comparison of the price bids.
c. Moreover, in case of delay in execution of the Contract by the Contractor beyond the stipulated period due to reasons not attributable to the Department, the Department will recover interest on the advance payment over the period of delay at the bank rate notified by State Bank of India applicable on the date of final acceptance of Fluid servicing system of Automated Continuous Cleaning.
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9.12.2Milestone Payment
a. The Department may release payments on completion of the following
major milestones. The milestone payments plus advance payment if
any agreed for shall not exceed 90% of the total contract value.
1. Design cost will be paid after final acceptance of Design by
the department.
2. Receipt of all the material at site- 80% of the cost of the
material received at IPRC site on PRO RATA BASIS
3. Erection & Commissioning- remaining from 90% of the
contract value
b. 100 % of the applicable taxes, duties, levies, etc will also be paid along
with the milestone payment claimed against actual delivery of the
material/service.
c. The invoice for each milestone payment for delivery of material shall be
accompanied by
i. Certification by the Department of having accepted the Pre-
Delivery Inspection (PDI) document
ii. Certificate of country of origin (for imported materials)
iii. Packing list/ Delivery Challan (DC) showing dimensions, gross
mass, net mass, quantity & content of packages
iv. Non-negotiable copy of Lorry Receipt (LR)/ Bill of Lading
(BL)/ Master Air Way Bill (MAWB)
v. Freight insurance policy
d. The invoice for each milestone payment for service shall be
accompanied by certification by the Department to the effect that the
Contractor has completed the service satisfactorily. The milestone
payment for design review & detail engineering will be made against
submission of BG valid till final acceptance of Fluid servicing system
for Automated Continuous Cleaning with additional claim period of 2
months.
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9.12.3Final payment
The balance of 10% of the total Contract price will be paid upon final
acceptance of Fluid servicing system for Automated Continuous Cleaning. The
invoice shall be accompanied by
a. Final acceptance certificate by the Department upon successful
completion of all contractual obligations by the Contractor, including
commissioning.
b. Warranty certificate
c. Performance Bank Guarantee
9.13 Mode of Payment
1. All payments to the Indian Contractor will be made through Public
Finance Management System.
2. All payments to the Foreign Contractor will be made by wire transfer.
3. The payments will be made within 30 days from the date of receipt of the
original invoice along with requisite and clean documents required as per
the Contract at the Department’s end.
4. Bank charges payable to their respective bankers shall be borne by the Department and contractor themselves
9.14 Pre-Qualification Criteria
The Bidder’s capability shall be evaluated based on the following Pre-
Qualification (PQ) criteria. The Bidders shall suitably fill-up the information
solicited in "Item Specification" and submit as part of the Techno-Commercial
Bid (TCB). Those Bidders who comply with the PQ criteria only will be
screened-in for opening and evaluation of Price Bid. The information to be
submitted in the TCB shall be complete in all respects substantiated by valid
documents and there shall not be any further opportunity for the Bidders to
submit any information or document unless the Department solicits so at their
own discretion.
Any lack of information or incomplete/ ambiguous information or false
information or information non-compliant with the PQ criteria shall be
treated as sufficient cause to summarily reject such Bids.
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9.15 Prior Turnover and prior experience:
The Bidder must comply with the following criteria on financial
soundness and prior experience:
9.15.1 The average annual financial turnover during last 3 years ending
31/03/2019 must be at least Rs 75 lakh. Escalation at the rate of 7% per
full year may be added on the annual turnover to arrive at the present
value as on 31/03/2019.
9.15.2 The Bidder shall attach audited balance sheet/ Annual report for prior
turnover.
9.15.3 The price of similar works successfully completed during last 7 years
ending 31/03/2019 must be as follows:
1 similar completed work costing not less than Rs 2 Crore OR
2 similar completed works costing not less than Rs 1.25 Crore each OR
3 similar completed works costing not less than Rs 1 Crore each.
Note:
(a) Engineering shall comprise design, detail engineering and analysis.
(b) Procurement shall comprise purchase of materials, quality control and
project management service.
(c) Construction shall comprise fabrication (offsite/ onsite), erection, testing &
commissioning.
9.15.4 The Work completion/ Final acceptance certificate issued by the Client in
favour of the Bidder or Inspection release note by Third Party Inspection
agency/ Consultant must be dated between 31/01/2011 and 31/03/2019.
Escalation at the rate of 7% per full year may be added on the price of
previously completed works to arrive at the present value as on
31/03/2019.
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9.16 Technical capability of Bidder:
9.16.1 The Bidder or Bidder along with proposed 1 or 2 subcontractor(s) shall
have capability covering piping, IPA and GN2 system. In any case, the
Contractor (successful Bidder) will have overall responsibility.
9.16.2 The Bidder shall mention, in the techno-commercial bid, whether they
propose to execute the Contract on their own OR they propose to engage
sub-contractor(s) for (i) Engineering AND/ OR (ii) Construction.
9.16.3 Group/ Parent/ subsidiary company of the Bidder may also be engaged
as subcontractor. The Contractor (successful Bidder) shall not be
permitted to change the Subcontractor upon award of Contract, till the
completion of work, without permission of the Department.
9.16.4 The Bidder shall give full information about their credentials/
subcontractor’s credentials substantiated by valid documents (Work
completion/ Final acceptance certificate issued by the Client in favour of
the Bidder/ subcontractor or Inspection release note by Third Party
Inspection agency/ Consultant) to comply with criteria mentioned
above. Experience shall pertain to works completed within 7 years
ending on 31-03-2019.
9.16.5 The Bidder and their subcontractor(s) must possess adequate & suitably
qualified and experienced in-house personnel at all levels such as
managerial, supervisory & tradesmen level and in the area of design,
procurement, fabrication & erection to execute the works given in this
document. The details shall be provided along with the techno-
commercial bid.
9.16.6 The Bidder and their subcontractor(s) must possess adequate facilities
(hardware & software) for design & detail engineering. The details shall
be provided along with the techno-commercial bid.
9.16.7 Bidder and their subcontractor(s) must possess adequate in-house
facilities such as equipments, machineries, testing facility and other
infrastructure to carry out factory fabrication and required facilities for
onsite erection. The details shall be provided along with the techno-
commercial bid.
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9.17 Execution plan
The bidder shall provide the execution plan for design review & detailed
engineering, purchase of materials, fabrication, erection and commissioning.
The bidder shall highlight the works proposed to be done in their own factory
and the works proposed to be done by their sub-contractors. The list of sub-
contractors from whom the bidder proposes to purchase the materials and the
sub-contractors with whom the bidder proposes to sub-delegate part of the
work shall be provided. The company profile of such sub-contractors/ sub-
contractors shall be given as per the requirements given in Section 5 volume-II.
The Department will have the right to scrutinise and to agree/ disagree with the
sub-contractors/ sub-contractors proposed by the bidder.
9.18. A Memorandum of Undertaking, as per the following format, shall be
submitted by the bidder along with the bid.
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MEMORANDUM OF UNDERTAKING
I/ We hereby submit the bid for the execution for the President of India of
the work specified in the underwritten memorandum within the time specified
in such memorandum, at a total price as specified and in all respects in
accordance with the specifications, design, drawings and instructions in writing
referred to in this document and with such materials as provided for by and in
all other respects in accordance with such conditions as are applicable.
Should this tender be accepted in whole or in part, I/We hereby agree to
abide by and fulfill all the terms and provisions of the said conditions annexed
here to and all the terms and provisions contained in the tender enquiry
documents which have been read by me/ read and explained to me so far as
applicable or in default thereof to forfeit and pay to the President of India or his
successors in office the sum of money mentioned in the said conditions.
I/ We agree to execute all the works referred to in the tender enquiry
documents upon the terms and conditions contained or referred to therein and
to carry out such deviation/ variation as may be ordered in excess of original
scope at the rates to be determined in accordance with the provision contained
in this document.
Witness Bidder (Signature) (Signature) Name: Name: Designation: Designation: Address: Address
For use by the Department only The above bid is hereby received by me on behalf of the President of India on __________ .
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10. Price details for Volume I-Mechanical System
S No Item Quantity Unit price Total price
1 Design review & Detail engineering
2 SS Pipes (*)
3 Pipe fittings (*)
4 Flexible hoses (*)
5 Manual valves (*)
6 EP valves (*)
7 Safety relief valves (*)
8 Filters (*)
9 Pressure regulators (*)
10 Non-return valve(*)
11 Pressure gauge(*)
12 Command Bottles(*)
13 Pump(*)
14 Tank(*)
15 Burst Disc(*)
16 Fabrication
17 Erection & Commissioning
18 Spares (*)
19 Taxes, duties, etc
20 TPI charges at contractor’s site
21 Packing & Transportation
Total price
(*) – Attach Separate Cost sheet for each component of that category
Table A : PRICE DETAILS
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10A. Price details for Volume I-Instrumentation System
Sl.
No.
Items Quantity Unit Unit price
Total Price
1. Absolute Pressure Transmitters 17 Nos
3 way manifold 17 Nos
Differential Pressure transmitters 6 Nos
5 way manifold 6 Nos
2. Temperature transmitter 6 Nos
3. RTD Probes including calibration cost
3 Nos
4. Transmitter communicator 1 No.
5. Mass Flow meter 3 Nos
6. Solenoid Valve 6 Nos
7. Guided wave radar based level sensor
2 No.
8. Junction boxes 3 Nos
9. PVC cables
20 AWG 2 core armoured cable 500 m
20 AWG 4 core armoured cable 200 m
18 AWG 2 core armoured cable 200 m
18AWG 64 Core Cable 100 m
20 AWG 64 Core Cable 100 m
18/20 AWG Single core PTFE wire (for internal rack wiring)
500 m
10. Cable trays & accessories 2 Sets
11. Structural materials 1 lot
12. Networking switch and cable 1 lot
13. Compression fittings and SS tubes 1 lot
14. Isolators
Isolators for transmitters. 32 Nos
Isolators for status 8 Nos
15. Relays 16 Nos
16. Contactor 2 Nos.
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17. Power supply :
24V±10%- 10A SMPS (Low ripple) (one set is 2 individual power supplies with diode oring mode)
3 Sets
18. Connectors and its accessories 5 Set
19. Instrumentation rack 1 No.
20. 3 segment Console 1 No.
21. Power cable 100 m
22. Earth cable 50 m
23. Terminal block
Terminal block- powering 200 Nos
24. Switches, Keys &indicators
Indicators 5 Nos
Authorization keys 2 Nos
Switches (in two position) with Indicators
2 Nos
25. MCBs 20 Nos
26. PLC based control system including 3 user PCs, operating software, SCADA, Printer, etc.
1 Set
27.
Spare 1. Processoe-1 no. 2. ALL I/O module each
type-1no. 3. PC-1 NO. 4. Printer-Black & white -
1 no.; Colour-1 no.
1 Set
Sub Total -1
B. ERECTION WORKS
1. Mounting of pressure transmitter and its impulse tubing
16 Nos
2. Mounting of Temperature sensor and its transmitter
5 Nos
3. Mounting of mass flow meter 2 No
4. Mounting of guided wave radar Level sensor and its transmitter
1 Nos
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5. Mounting of 5 SOVs with E/P valve 5 Nos
6. Mounting of Junction box 2 Nos
7. Cable lying
8. Rack wiring
9. Realization of SCADA based PLC with all measurements, control & command lines, 3 PCs, printer, Positioning of racks inside instrumentation room, etc
0
10. Detailed engineering
11. Training
12. Commissioning
13. Post warrantee Programming support services
14. AMC for 3 years
15. Testing and Evaluation
16. Documentation 1 lot
Sub Total -2
TOTAL
Volume II
VOLUME II
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1.A. SPECIFICATION OF MECHANICAL SYSTEMS 1.A.1 Pipes
Type : Seamless pipes
Nominal Pipe size & Scheduled number
: As per P&ID (Refer Table-1/Annexure V)
Length : As required on the isometrics, to be
prepared by the contractor
Material : ANSI B 36.19/36.10, ASTM A-312, T.P.
304L/316/321
Dimensional standard : ASME B 36.19 up to SCH 80S/ ASME B36.10 above SCH 80S
TESTS Visual examination: All pipes shall be visually examined for workmen-like finish. Dimensional check: One specimen from each lot shall be subject to dimensional check. Chemical analysis: One specimen from each lot shall be subject to detailed chemical analysis as per ASTM A 751 Mechanical tests: One specimen from each lot shall be subject to tests for mechanical properties per ASTM A 370 (including Impact test.) Hydraulic pressure test: All pipes shall be hydraulically pressure-tested with water as per ASTM A 530. Ultra-sonic test: All the SS pipes of size ≥ DN 25 shall be subject to Ultra-sonic test (100 %) by Contact or pulse echo method as per ASTM A 450.
Eddy current test: All the SS pipes of size 20 NB shall be subject to eddy current test as per ASTM E 426. Flattening test: Pieces of pipes of length 63.5mm (2.5”) cut form the ends of 5% of pipes lengths per lot shall be subject to flattening test as per ASTM A 530 in 2 steps to prove ductility and soundness.
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Inter-granular corrosion test: One specimen per lot shall be subjected to inter-granular corrosion test as per ASTM A 262 (practice A/E). Pickling & Passivation: All pipes shall be pickled & passivated. Cleanliness: The pipes shall be cleaned and dried before dispatch. Marking: The pipes shall be marked as per ASTM A 700. 1.A.2 Pipe fittings
Size, pressure Rating and quantity
: As required based on P&IDs and isometric drawings to be prepared by the contractor.
Type :
Butt welded fittings for fluid circuits
Standard : Flanges: ANSI B 16.5 Butt welded fittings: ANSI B 16.9
Material : Flanges ASTM A 182 F 304L/316L Butt welded fittings: ASTM A 403 WP 304L/316L
Visual examination: All fittings shall be visually examined for any scratches, dents, surface irregularities, etc.
Dimensional check: One specimen from each lot shall be checked for dimensions as per the standard. Chemical analysis: One specimen from each lot shall be subject to detailed chemical analysis. Mechanical tests: One specimen from each lot shall be subject to mechanical test to verify mechanical properties.
Inter-granular corrosion test: One specimen per lot shall be subjected to inter-granular corrosion test as per ASTM A 262 (practice A/E)
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1.A.3 Manual valves/bellow seal valves
Tag No, pattern,
configuration of
ports/ ways, fluid
medium, working
temperature range,
size, MAWP,
Pressure rating class
:
As given in Table 2/ ANNEXURE-V
Actuation : Hand operated (manual)
Application : Isolation
Valve coefficient : To be specified by the bidder in the
quotation
Permissible leakage
rate across body
: 1E-06 Pa-m3/s for gland packing globe valves
Permissible leak rate
across seat
: 1E-06 Pa-m3/s for resilient-seated globe valves
1E-05 Pa-m3/s for hard-seated globe valves
Guaranteed cycles of
operation
: 5,000
End connection
BW: Butt welding ends as per ASME B 16.9/ 16.25. In case of valves with resilient seat, pipe stubs as per ASME B 36.19/ 36.10 of 150 mm length each shall be butt-welded to the body on either side, the ends of which shall be prepared for butt welding.
Style of construction:
Body : With full port (standard bore) and in-line
end connections
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Bonnet
: Bolted or screwed to body with spring-energised seals
(Such as Helicoflex, Enerseal, etc)
Stem (dynamic) seal : By gland packing for GN2 media.
Plug : Renewable (replaceable) from stem with
insert
Seat : Integral with body of material harder than
the plug insert.
Flow direction : Flow to open and all the valves shall have bi-
directional shut-off.
Material of construction:
Body and Bonnet : ASTM A182F 304 L / 316L / 321 For
≤DN40
ASTM A351 CF3 /CF3M For ≥DN50
Stem, plug, seat : ASTM A479 304L/ 316L/ 321
Gland packing : PTFE/ Glass-filled PTFE
Plug and seat inserts : PCTFE (Kel-F) / Poly-carbonate for MAWP ≤ 250 bar
ASTM A 479 304L/ 316L with # 6 stelliting for MAWP > 250 bar.
Pipe stub : ASTM A312 TP 304L/ 316L (pipe stub
length 50mm)
Bolts : ASTM A 193 B 8
Nuts : ASTM A 194 8
Note:
1. The valves shall be either inherently anti-static or provided with anti-static features.
2. Dual marking material (SS304L/304 or SS316L/316) is also acceptable wherever applicable.
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Design code : BS 5352/ BS 6364/ API 6-D/ ANSI B16.34
Test code : BS 6755/ API 598
Tests: Material certificates: The material certificates, detailing the physical and chemical properties, of the principal pressure-bearing parts shall be provided.
Welding joint test: Any butt welding joint in the valve shall be subject to DP Test, radio-graphic test with X-rays or gamma rays to 2-2T sensitivity. Soundness test for castings: All the castings shall be subject to soundness test with radio-graphic test with X-rays or ultra-sonic technique for flaw detection. Hydraulic shell pressure test: The valve shall be upon assembly subject to pressure test with Water (with suitable corrosion inhibitor) at 1.5 times the maximum rated working pressure of the particular pressure rating class of the valve. The test procedure and acceptance criteria shall be as per BS 6755 part 1 or API 598 or ANSI B 16.34. Hydraulic seat pressure test: The valve, in closed position, shall be subject to pressure test with water (with suitable corrosion inhibitor) at 1.1 times the maximum rated working pressure of the particular pressure rating class of the valve. The test procedure and acceptance criteria shall be as per Rate A of BS 6755 part 1 or API 598 or ANSI B 16.34.
Pneumatic seat leak test (for ball valves only): The Leak rate across the seat of ball valves shall be tested with dry air or GN2 at 4 to 7 bar by water displacement (bubble) method. The acceptance criteria shall be as per Rate A of BS 6755 Part 1 or API 598 MSLD shell leak test: (For globe valve only) The global leak rates across body shall be measured with GHe MSLD to establish the leak tightness values specified above by hood technique as per Article 10, Section V, ASME. The leak test shall be performed by shrouding the entire outside surface of the valve with a plastic bag to hold GHe at a positive pressure and by evacuating and connecting the inlet/ outlet port to MSLD. Leak test by detector probe or tracer probe technique is not acceptable.
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MSLD seat leak test (for globe valves only): The global leak rates across seat
shall be measured with GHe MSLD to establish the Leak tightness values
specified above by hood technique as per Article 10, Section V, ASME. The leak
test shall be performed by pressurising the inlet with GHe and by evacuating
and connecting the outlet to MSLD. Leak test by detector probe or tracer
probe technique is not acceptable.
Functional test: The valve with all accessories mounted shall be subject to functional test to validate the performance.
Cleanliness: All the interior flow surfaces of the valve shall be degreased and
cleaned to O2 service standards as per CGA G-4.1 or MIL-C-52211 or ASTM
G-93.
Marking: All the valves are assigned tag numbers for the sake of identification. The tag number for each valve, as indicated above, besides size, pressure rating class, material of construction, etc, shall be legibly and indelibly engraved on the body of the valves.
1.A.4 Electro-Pneumatic Valves The electro-pneumatic (EP) valve shall comprise valve, actuator, solenoid valve and limit switches.
Valve
Actuation : Electro-pneumatically operated.
Tag No, pattern, Configuration of ports/ways, fluid medium, working temperature range, size, MAWP
: As given in Table 3/ Annexure -V
Other specifications : As specified for manual valves in section 1.3
Length of stem extension : As per BS 6364
ACTUATOR
Type : Linear actuator, piston/ diaphragm type,
single acting, spring return, fail-safe
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Normal position : As given in Table 3/ ANNEXURE-V
Response time (for
both opening and
closing strokes)
:
As given Table 3/ ANNEXURE-V
If required, flow (volume) booster and quick
exhaust valve shall be incorporated to
achieve the specified response time.
End connection for
command gas
: DN 8 (¼”) NPT(F) to ASME B 1.10.1.
Material : Carbon steel (enamel-painted)
Test : The response time taken for opening and
closing of the valve shall be evaluated.
STATUS SWITCHES The valve shall be provided with a pair of non-contact type proximity
status switches to indicate the “opened/ closed” status of the valve. The
status switches shall be mounted on the valve with such proper
arrangement that does not require any adjustment/ alignment for the
specified cycles of operation of the valve.
Type : Cylindrical Inductive Type Proximity
Sensor (switch) in accordance with
NAMUR
Sensing Distance : 1.5, 2, 4, 5 mm (The sensing distance
shall be suitably selected by the valve
manufacturer according to the valve
stroke length)
Electrical configuration : DC, 2 wire
Nominal voltage : 8 V
Operating voltage : 5 – 24V
Switching frequency : > 500 Hz
Reverse polarity : Shall be Protected against reverse
polarity
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Short circuit protection : Shall be Protected for short circuit
Current
Consumptio
n
Not sensing : ≥ 3mA
Sensing : ≤ 1mA
Indication of switching
state
: LED
Connection Type : 2 m long PVC cable
Ambient Temperature : -240 C to 800 C
Housing material : Stainless steel
Protection Degree : IP 67
Hazardous area
certification
: The switches shall be intrinsically
safe for Hydrogen environment in
conformance with Ex ia IIC T6,
Zone 1 of IEC/ ATEX. The
certificate of conformance to this
effect from the accredited agency
shall be provided.
Make and model : To be specified by the bidder in
the quotation.
Suggested make
: a. IFM electronic b. Omron, USA c. Pepperl + Fuchs, Germany d. Rockwell Automation – USA e. LongVale ltd – UK f. Cario Gavazzi g. Euroswitch – UK
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1.A.5 TECHNICAL SPECIFICATION OF SAFETY RELIEF VALVES
Tag number : As given in Table 4/ ANNEXURE-V
Type : Balanced bellow type
Extent of lift : Full lift
Fluid medium : As given in Table 4/ ANNEXURE-V
Working temperature range
: As given in Table 4/ ANNEXURE-V
Set pressure : As given in Table 4/ ANNEXURE-V
Flow temperature : As per design standard
Minimum required gas flow capacity
: To be sized by the contractor
Orifice designation (area)
: To be sized by the contractor
Over-pressure : ≤ 10 % of set pressure
Blow-down : ≤ 7 % of set pressure
Permissible leakage
rate across seat
:
As per API 527
End connection : Raised Face (RF) flanges with concentric
serrations for pressure rating class ≤ 1500
as per ASME B 16.5 and
Ring Joint (RJ) flanges for pressure rating
class ≥ 2500 as per ASME B 16.5
NPT as per 1.20.1 for screwed valves
(The bidder shall specify in the
quotation the nominal size and pressure
rating class of the flanges at inlet and
outlet)
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Material of construction:
Body, bonnet :
ASTM A 351 CF3/3M/8/8M (for conventional
& bellow balanced valves)
ASTM A 182F304/304L/316 / 316L (for
screwed valves)
Nozzle
:
ASTM A182F304/304L/316/ 316L (for set pr.≤
15 MPa)
ASTM A182F304/304L/316/ 316L stellited (for
set pr.> 15 MPa)
Disc
: Viton (for set pr.≤1 MPa & op. temp. 300 K)
PTFE (for set pr.1 to 15 MPa & op. temp. 75 to
300 K)
PCTFE (for set pr.< 15 MPa & op. temp. <75 K)
ASTM A182F304/304L/ 316/316L stellited (for
set pr.> 15 MPa)
Guide : ASTM A 297 Gr HE
Bellows (for valves
of balanced bellow
construction)
: Stainless steel 316L/ 316Ti/ 321/
Spring : Stainless steel 316L
Bolts : ASTM A 320 B 8
Nuts : ASTM A 194 8
Design code : API 526/ ASME Section VIII, Division /CGA-
S-1.2, 2009/ISO 21013-3,2016
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Tests:
a. Material certificates: The material certificates, detailing the physical and chemical properties, of the principal pressure–bearing parts shall be provided.
b. Soundness test for castings (wherever applicable): All the castings shall be subject to soundness test with radiographic or ultrasonic technique for flaw detection.
c. Seat leakage test: As per API 527 d. Cold differential set pressure test: To validate set pressure e. Hydrostatic test of nozzle: All the nozzles / base of the valves shall
be subject to hydrostatic test as per Code.
Cleanliness
All the interior flow surfaces of the valve shall be degreased and cleaned
to Oxygen service standards as per CGA G-4.1 or ASTM G 93.
Marking
All the valves are assigned tag numbers for the sake of identification. The
tag number for each valve, as indicated above, besides manufacturer, set
pressure, size & pressure rating class of inlet & outlet connections,
material of construction, etc, shall be legibly and indelibly engraved on
the body of the valves.
1.A.6 Filters
Tag number, fluid medium, working
temperature range, size, MAWP,
fineness of filtration (absolute), inlet
temperature, inlet pressure,
permissible pressure drop, flow rate,
end connection
: As table 5/
ANNEXURE-V
End connection : BW: Butt welding ends as per ASME B
16.9/ 16.25. In case of filter with internal
resilient seals, pipe stubs as per ASME B
36.19/ 36.10 of 100 mm length each shall
be butt-welded to the body on either
side, the ends of which shall be prepared
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for butt welding. The butt welding ends
shall be suitable to mate with the
interfacing pipe of schedule number as
given in Table 5/ ANNEXURE-V
Permissible leakage rate
across the body (external)
: 1E-7 Pa-m3/s for filters for fluid medium of liquid Hydrogen, liquid Oxygen, liquid Nitrogen, gaseous Hydrogen
Style of construction:
Body : Y or T type with access to replace the
filter element cartridge without
removing the filter en-masse from
pipeline. For sizes ≤DN50, Filters are
preferred in bi-directional type.
Filter element : Sintered wire mesh type, supported on
perforated cartridge
Material of construction:
Body : ASTM A182F 304 L / 316L / 321 For
≤DN40
ASTM A351 CF3 /CF3M For ≥DN50
Alternatively, the material of
housing of filters of size ≥ DN50
may be fabricated using standard
pipes, caps, pipe fittings, etc of
material SS 304L/ 316L subject to
following:
a. Pipes of size ≤ DN 300 shall be
seamless and sizes ≥ DN 350 shall
be of welded or seamless.
b. The parent/ raw materials (pipes,
caps, pipe fittings, etc) used shall
be subject to 100% ultrasonic test.
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c.The welding joints (including
longitudinal seam joint of welded
pipes) shall be subject to 100 %
radiographic test.
d. The drawings are to be specifically
reviewed the Department before
fabrication.
Mesh : Stainless steel 304L/ 316L/ 321
Internal seals : PTFE/ Glass-filled PTFE for filters with lower limit of working temperature range ≥ 75 K
PCTFE/ Poly-carbonate for filters with lower limit of working temperature range < 75 K
Viton/ PTFE for filters with working temperature range 290 to 350 K
Bolts : ASTM A 320 B 8
Nuts : ASTM A 194 8
Note: Dual marking material (SS304L/304 or SS316L/316) is also
acceptable wherever applicable.
Tests:
a. Material certificates: The material certificates, detailing the physical
and chemical properties, of the principal pressure–bearing parts
shall be provided.
b. Welding joint test (wherever applicable): All butt welding joints in
the filter shall be subject to radiographic test with X-rays or gamma
rays to 2% equivalent sensitivity as per Section IX, ASME.
c. Soundness test for castings (wherever applicable): All the castings
shall be subject to soundness test with radiographic or ultrasonic
technique for flaw detection.
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d. Hydraulic shell pressure test: The filter, upon final assembly shall
be subject to pressure test with Water (with suitable corrosion
inhibitor) at 1.3 times the maximum allowable working pressure.
e. MSLD shell leakage test (for filters with fluid medium gaseous
Hydrogen, gaseous Helium and Vacuum): The global leakage rate
across body shall be measured with gaseous Helium Mass
Spectrometer Leakage Detector (MSLD) to establish the permissible
leakage rate values specified above by hood technique as per Article
10, Section V, ASME. The leakage test shall be performed by
shrouding the entire outside surface of the filter with a plastic bag
to hold gaseous Helium + gaseous Air mixture at a positive
pressure and by evacuating and connecting the inlet/ outlet port to
MSLD. Leakage test by detector probe or tracer probe technique is
not acceptable.
f. Degree of filtration test: One sample filter element cartridge from
each batch of the same size shall be subject to “micron rating”
prototype test by bubble point method and microscopic
examination to evaluate minimum and maximum pore size of the
filter element in Government-approved laboratory.
Cleanliness
All the interior flow surfaces of the filter shall be degreased and
cleaned to Oxygen service standards as per CGA G-4.1 or ASTM G 93.
Marking
All the filters are assigned tag numbers for the sake of identification.
The tag number for each filter, as indicated above, besides
manufacturer, size, maximum allowable working pressure, degree of
filtration, material of construction, etc, shall be legibly and indelibly
engraved on the body of the valves
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1.A.7 TECHNICAL SPECIFICATION OF NON-RETURN VALVES
Tag number : As given in Table 6/
ANNEXURE-V
Type Plug Type
Fluid medium : As given in Table 6/
ANNEXURE-V
Working temperature range
: As given in Table 6/
ANNEXURE-V
Nominal size : As given in Table 6/
ANNEXURE-V
MAWP : As given in Table 6/
ANNEXURE-V
Seal : Soft seating KELF gasket
End connection :
BW: Butt welding ends as per ASME B 16.9/ 16.25. In case of valves with resilient seat, pipe stubs as per ASME B 36.19/ 36.10 of 100 mm length each shall be butt-welded to the body on either side, the ends of which shall be prepared for butt welding.
Flanged: Raised Face (RF) flanges with serration for pressure rating class ≤ PN 250 and Ring Joint (RJ) flanges for pressure rating class ≥ PN 420 as per ASME B 16.5.
Permissible leakage
rate across body
: 1E-6 Pa-m3/s for valves for fluid medium of liquid Nitrogen, gaseous nitrogen and gaseous Helium
Bubble-tight as per API 598 or Rate A as per BS 6755 Part 1 for valves for other fluid media
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Permissible leakage
rate across seat at a
pressure differential of
0.2 MPa(d) along non-
flow (reverse) direction
: Bubble-tight as per API 598 or Rate A as per BS 6755 Part 1 for soft seated valves
As per FCI70.2 for metal seated valves
Style of construction: Lift mechanism
: Lift plug type, globe pattern for valves of nominal size ≤ DN 100
Swing/ butterfly/ dual plate type for valves of nominal size > DN 100
Cover : Screwed or bolted to body with
suitable seals
Plug : Renewable (replaceable) from
stem with insert
Material of construction
Body, cover :
ASTM A 182 F 304L/ 316L/ 321 for nominal size ≤ DN 40
ASTM A 351 CF 3/ 3M for nominal size ≥ DN 50
Stem, plug : ASTM A 479 304L/ 316L/ 321
Plug insert/ trim : PCTFE (Kel-F)/ Poly-carbonate for working temperature < 75 K and pressure rating class ≤ PN 250
ASTM A 479 304L/ 316L/ 321 for pressure rating class ≥ PN 420.
Bolts : ASTM A 320 B 8
Nuts : ASTM A 194 8
Note: Dual marking material (SS304L/304 or SS316L/316) is
also acceptable wherever applicable.
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Tests:
a. Material certificates: The material certificates, detailing the
physical and chemical properties, of the principal pressure–
bearing parts shall be provided.
b. Welding joint test (wherever applicable): All butt welding
joints in the valve (including the joints between the body and
the pipe stubs) shall be subject to radiographic test with X-
rays or gamma rays to 2% equivalent sensitivity.
c. Soundness test for castings (wherever applicable): All the
castings shall be subject to soundness test with radiographic
or ultrasonic technique for flaw detection.
d. Hydraulic shell pressure test: The valve, upon final assembly,
shall be subject to pressure test with Water (with suitable
corrosion inhibitor) at 1.5 times the maximum rated working
pressure of the particular pressure rating class of the valve.
e. MSLD shell leakage test (for valves for fluid medium of, IPA,
gaseous Nitrogen and Gaseous helium): The global leakage
rate across body shall be measured with gaseous Helium
Mass Spectrometer Leakage Detector (MSLD) to establish the
permissible leakage rate values specified above by hood
technique as per Article 10, Section V, ASME. The leakage test
shall be performed by shrouding the entire outside surface of
the valve with a plastic bag to hold gaseous Helium +
gaseous Air mixture at a positive pressure and by evacuating
and connecting the inlet/ outlet port to MSLD. Leakage test
by detector probe or tracer probe technique is not acceptable.
f. Seat leakage test: The leakage rates across seat in flow and
non-flow directions shall be measured with gaseous nitrogen
/ dry Air to establish the permissible leakage rate values
specified above by bubble emission method.
Cleanliness
All the interior flow surfaces of the valve shall be degreased and
cleaned to Oxygen service standards as per CGA G-4.1 or ASTM
G 93.
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Marking
All the valves are assigned tag numbers for the sake of
identification. The tag number for each valve, as indicated
above, besides size, pressure rating class, material of
construction, etc, shall be legibly and indelibly engraved on the
body of the valves.
1.A.8 Pressure regulators
Tag number, fluid :
medium,
type of loading, inlet
pressure range, outlet
pressure range, flow rate,
inlet pipe size, outlet pipe
size
As given in Table 7 / ANNEXURE-
V
Working temperature :
range
290 to 350 K
Flow temperature : 310 K
Orifice size : To be decided by the Contractor
Balancing : Balanced valve assembly
Venting : Self venting
Repeatability of :
regulation (droop)
< 1 % between the set pressures at the minimum and maximum controllable flow rates
≤ 3 % between the locked up pressure and the minimum set pressure
Ratio of variation of : set pressure to variation in inlet pressure (Decay ratio)
< + 1 %
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Permissible leak rate :
across seat (through) in closed condition
1E-04 mbar-l/s
Permissible leak rate : across body (external)
1E-05 mbar-l/s
Materials of construction:
Body, trim : ASTM A 182 F 304L/ 316L
Seals, O-rings : Viton/ Buna N
End connection : Threaded swivel union with sphere-and-cone metallic line contact seat (Alternatively, elastomeric seals may be used, if compatible for the working temperature and pressure)
Cleanliness : Same as that of manual valves
Tests:
Material test for mechanical properties and chemical
composition.
Pneumatic pressure test with GN2 or dry Air at 1.1 times the
maximum set pressure.
Leak test with GHe MSLD.
Functional test.
Each pressure regulator shall be fitted with a filter at the inlet of
rating as listed in Table-5/Annexure V. The specification of these
filters shall be the same as that specified in Section 5.6.
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1.A.9 TECHNICAL SPECIFICATION OF PRESSURE GAUGES
Quantity : As given in Table 8/ ANNEXURE-V
Tag number : As given in Table 8/ ANNEXURE-V
Type : Bourdon tube
Fluid medium : As given in Table 8/ ANNEXURE-V
Working temperature
range
: 290 to 350 K
Range : As given in Table 8/ ANNEXURE-V
Unit : MPa(g) and bar(g)
Dial size : To be specified by Contractor during
DER
Scale : Concentric
Accuracy : ±1.6 % of FSD for gauges with 50mm
dial and ±1 % for other gauges.
Over-range protection : 130 % of FSD
Material of construction
of sensing element,
movement, socket, case,
bezel
: Stainless steel 304L/ 316L/ 321
Window : Shatter-proof
Process connection : DN 8 (¼”) NPT(M) for gauges with 50 mm dial and DN 15 (½”) NPT(M) for other gauges
OR
¼” Face Seal Fittings for gauges with 50 mm dial and ½” face seal fittings for other gauges
Mounting : Direct mounting, bottom entry
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Case and bezel : Weather-proof housing with screwed
outer bezel
Extra fitments : Micro-type adjustable pointer Blow-out-proof disc
Joints : Gas Tungsten Arc Welding (GTAW)
with gaseous Argon purge
Code : IS 3624/ EN 837-1
Tests
a. Material certificates: The material certificates, detailing the physical
and chemical properties, of the principal pressure–bearing parts shall
be provided.
b. Calibration: The pressure gauges shall be calibrated with IPA/GN2
as per Code.
Cleanliness
All the interior flow surfaces of the pressure gauge shall be degreased
and cleaned to Oxygen service standards as per CGA G-4.1 or ASTM
G 93.
Marking
All the pressure gauges are assigned tag numbers for the sake of
identification. The tag number for each pressure gauge, as indicated
above, besides size, pressure rating class, material of construction, etc,
shall be legibly and indelibly engraved on the body of the pressure
gauges.
1.A.10 Command gas bottles
The details are listed in Table-9/Annexure V.
Design Data
Design Code : ASME Sec.VII Div.I,(Latest)
Volume (Water Capacity) :10 lit
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Service Medium : GN2
Quantity : As per table-9/Annexure-V
Max Allowable Working Pr. : 20 bar for GN2
Working Temperature : 290 – 350 K
Corrosion allowance : 1.5 mm
Mounting : Horizontal
Dished Ends : Torispherical/ellipsoidal
Material Of Construction
Shell , Dished Ends : ASTM A 240 Gr 304 / 304 L/316L
Pipes : ASTM A 312 TP 304/304 L/316L
Flanges : ASTM A 182 F 304 / 304 L/316L
Gasket : SS 304 With spirally wound PTFE
Bolts : SA 193 Gr B – 8
Nuts : SA 194 Gr B – 8
Nozzle details : Inlet - 15 NB
Outlet - 15 NB
Material Testing
The material to be used for fabrication shall be tested for their physical
and chemical properties and it shall be carried out in a government
approved laboratory.
Fabrication
1. The dished ends shall be stress relieved after forming. 2. All the welding shall be performed by Gas-Purged
Tungsten Arc welding (GTAW) process with argon as the purge gas in accordance with the relevant code.
3. The bottle shall be provided with suitable saddle supports , lifting lugs , and name plate.
4. All the nozzles <50mm dia. shall be stiffened with gusset plates.
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5. All the nozzles flanges shall be provided with mating
blind flanges ( including gasket , bolts and nuts).
Testings
NDT & Hydro – static shall be carried out as per code requirement.
Cleaning
Chemical cleaning ( degreasing , picking & passivation) shall be
carried out as per the standard procedure and specification.
1.A.11 Pump
Item name : Magnetic Coupled Sealless pump
Quantity : As given in Table 10/
ANNEXURE-V
Tag number : As given in Table 10/
ANNEXURE-V
Type : Centrifugal
Fluid medium : As given in Table 10/
ANNEXURE-V
Working temperature
range
: 280 to 310 K
Flow rate : 21 m3/hr(max)
Suction Lift : 2.2 meter
Head : 30 meter
Medium : Iso Propyl alcohol
Temperature : Max 100°C
Power : 3.7 KW
RPM : 2900
Frequency : 50 HZ
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The pump should be compatible with variable feed drive and provide
varying flow rates.
It shall be of flame-proof construction and all fittings should be of 2B
(flame proof) construction.
1.A.12 Run Tank & Collection Tank:
Type : Cylindrical with both ends ellipsoidal dish
Size : As per table-11/Annexure-V
Water capacity : 3000 litres for Run Tank, 1000 litres for Collection Tank
Material : SS 304 L
Design Pressure : 5 bar
Design Temperature : 55°C
Fluid handled : Iso Propyl Alcohol
Corrosion allowance : 1.5mm
Joint Efficiency : 1.0
Design code : ASME SEC VIII DIV 1 2004 (or recent addenda)
Nozzle detail : As per Drawing : SAIE/CUSAIG/CSCF/001 with minimum standoff distance of 150mm
Additional requirement : Suitable lifting lugs & mounting brackets
Non-Destructive Testing(NDT)
: 1. Final Welds: 100% DP & RT with minimum of
2% sensitivity on all but welds and 100% DP on all fillet welds.
Mounting : Vertical
Quantity : As per table-11/Annexure-V
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Design:
a. The tank shall be designed as per the data furnished in table-
11/Annexure-V
b. Support and mounting brackets are to be designed.
c. Party should send the fabrication drawing along with design
calculation with TPI clearance for approval prior to start of
procurement of raw materials.
Material:
Materials of construction are as per the following table.
Sl.No. Item Material
1. Tank cylindrical portion SS 304 L
2. Tank dome SS 304 L
3. Nozzle SS 304 L
4. Flanges SS 304 L
5. Bolts/studs SS 304
6. Nuts SS 304
7. Mounting bracket, weld pads SS 304
8. Lifting lugs SS 304
9. Gaskets SS 304 L Spiral wound Teflon
Fabrication:
1. All SS welding shall be done in GTAW process.
2. Filler wire shall confirm to A120 or equivalent.
3. All the butt welds shall be DP tested and radio-graphed (size of weld
has to be mentioned in the fabrication drawings)
4. All fillet weld shall be 100% DP tested.
5. Dished ends have to be stress relieved after forming.
6. All nozzles shall be covered with blind flanges, bolts, nuts & gaskets.
7. Nozzles shall be stiffened with 2 nos. of gussets at 90º apart.
8. All the weldings has to be carried out by qualified welders.
9. Name plate & bracket shall be provided for the tank.
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Cleaning:
The tank has to be mechanically cleaned by buffing wheel, degreased
after hydraulic test according to the procedure given below.
Mechanic Cleaning:
All surfaces inside and outside having scales and foreign
materials have to be cleaned. This can be done by;
a. Scrubbing with metallic brush
b. Sand blasting (iron free sand) and the loose scales and
powders obtained from the above process shall be cleaned by
blowing or washing.
1. Degreasing:
This is to remove oil and grease. This can be achieved by
vapour phase degreasing using trichloroethylene.
2. Pickling: (for inside surface only)
This is carried out after mechanical cleaning and degreasing
operations to remove all the rusts and scales. Following are the
guidelines for carrying out the same.
a) Cleaning with water.
b) Pickling with a solution containing Hydrofluoric and nitric acid.
c) The composition of the pickling solution and duration of
pickling are adjusted after trial test on a sample piece to remove
uniformly less than 25 Micron thick materials. Mostly the
composition is 5% Hydrofluoric acid (by wt) + 15 to 20% Nitric
acid (by wt) + balance water at ambient temperature.
3. Passivation: (for inside surface only)
This is to be done after the pickling operation. A solution
containing 25% HNO3 (by vol) and 75% water (by vol) at ambient
temperature will be used for this purpose. Duration of the passivation
should be 2 hours minimum. Finally rinsing with de-mineralised
water is to be carried out.
Note: After the process, no mechanical cleaning should be attempted.
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a. The cleaned surface is to be checked by using a white filter paper.
Rubbing of the paper on the surface should not change the colour of
the paper.
b. By analyzing the final used water the quality of cleaning can be
checked. The rinse water should not have suspended particles
more than 20mg/m2 (based on surface area). The pH value of the
de-mineralised water must be between 6.5-7.5.
4. Drying:
The drying is done to remove water and is to be done by
purging with Nitrogen having dew point less than -25°C and free from
oil and grease (less than 10ppm) at 60°C till the moisture level at the
exit comes to the inlet concentration.
5. Sealing:
After drying, the tanks should be sealed so that ambient
moisture cannot enter inside. The tanks are to be pressurized to 50
m.bar (Kg) with dry N2 gas.
1.A.13 Flexible Hoses( Table12/Annexure-V)
Material:
Inner corrugation : SS316/316L
Braided wire : SS304/304L
End fittings : SS304/304L
Quality Clause for Flexible Hose:
The hose shall consists of seamless stainless steel inner tube
reinforced with corrosion resistant steel wires. End fittings shall be as
per DIN standard. The hose assemblies should be qualified to latest
revision of MIL standard (Type-II conductive inner tube).
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Scope of Inspection:
Visual Examination:
The hose shall be free from oil, grease, dirt or any other foreign material
both internally and externally. Broken or missing reinforcement wires
shall be cause for rejection.
Dimensional Inspection:
The hose and end fittings shall meet the requirements as per approved
drawings.
Proof Pressure Test:
The hose shall be subjected to proof pressure test to a pressure of
1.5 times the operating pressure successfully.
Radiography:
100% radiographic examination at crimping points should be done after
proof pressure test. No crack or damage is acceptable.
Material Test:
Material test certificates (Mechanical & Chemical) for PTFE, end fittings
& SS PIPING.
Pneumatic Leak test:
The hose is to be pressurized with Helium gas inside to 2.5 bar. The
leak rate is to be detected by MSLD and the acceptance rate is
<5 x 10-5 atm cc/sec.
GN2 effusion test:
The hose assembly shall be subjected to operating pressure with GN2 at
room temperature. Gas effusion shall be collected using water
displacement method and air collecting device. The total amount of
effusion through the hose and fittings shall be collected over the last 30
minutes of testing.
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Identification:
Part No., Operating & Proof pressure test details to be engraved
in the tag of hose assembly as per table-12/Annexure-V.
Packing:
The hoses shall be provided with suitable Aluminium alloy end
closures to avoid damage during transportation and each hose is to be
packed separately along with dehydrant bag.
1.A.14 Burst Disc
Quantity : As per table -13/Annexure-V
Tag number : As per table -13/Annexure-V
Type : Scored metal, pre-torqued, rupture
disc devices, along with safety
heads, studs and nuts.
Mode of buckling : To be specified by the bidder in the
quotation (forward/ reverse)
Fluid medium : IPA
Working temperature range : 288-323K
Burst pressure : As per table -13/Annexure-V
Flow temperature : 288-323K
Minimum required flow
capacity
: As per table -13/Annexure-V
Orifice diameter : To be specified by the bidder in the
quotation
Burst tolerance : 5 %
Material of construction:
Disc : Inconel
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Safety head : ASTM A 182 F 304L/ 316L/ 321
Studs : ASTM A 320 B 8
Nuts : ASTM A 194 8
Tests:
a. Material certificates: The material certificates, detailing the physical and chemical properties, of the principal pressure–bearing parts shall be provided.
b. Burst test: As per UG-127, Section VIII, Division 1, ASME.
c. Dimensional check: After forming, the dimensions of the disc, especially the thickness, shall be measured and recorded.
Cleanliness
All the interior flow surfaces of the device shall be degreased and cleaned to
Oxygen service standards as per CGA G-4.1 or ASTM G 93. (Strike out if not
applicable.)
Marking
All the devices are assigned tag numbers for the sake of identification. The
tag number for each device, as indicated above, besides nominal size, burst
pressure, pressure rating class of the safety heads, material of construction of
disc, etc, shall be legibly and indelibly engraved on the body of the devices.
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1.A.15 Spray Nozzle
1. Flow medium : Iso propyl Alcohol
2. Orifice slit size : 4mm x 5mm
3. No. of slits in a nozzle : 4
4. Nozzle Diameter : 80mm to 100mm
5. Nozzle Height : 185mm to 200mm
6. Quantity : 4
7. Materials
Housing : SS316L
Bush/seals : PTFE
Nozzle head : SS316L
Gears : PEEK and SS316
8. Max. working temp : 160°C
9. Working pressure : 3 to 10 bar
10. Flow rate : 40 to 160 litre/minute
11. Interface size : 1”NPT female
12. Nozzle shall rotate 360°during operation.
13. The nozzle shall have variable cycle time according to variation in inlet
pressure.
14. Nozzle shall have provision for self cleaning and self lubrication.
15. Nozzle shall have high impact jets, orbital wash pattern with high
efficiency cleaning process.
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1.A.16 Vacuum Breaker :
Type : Tec –Vent Air Admittance valve
Tag Number : As per table-14/Annexure-V
Material : Membrane - synthetic rubber Cap & body – Flame-retardant polycarbonate
Design Pressure : 5 bar
Design Temperature : 310 K
Fluid handled : Iso Propyl Alcohol
Opening Pressure : -70 Pascal
1.A.17 Filter Bag :
Volume : 1000 ( L )
Quantity : As per table-15/Annexure-V
Media Material : PIFE
Design Temperature : 310 K
Fluid handled : Iso Propyl Alcohol
Filtration Precision : 100 micron
Fabrication:
1. All SS welding shall be done in GTAW process.
2. Filler wire shall confirm to A120 or equivalent.
3. All the butt welds shall be DP tested and radio-graphed (size of weld
has to be mentioned in the fabrication drawings)
4. All fillet weld shall be 100% DP tested.
5. Dished ends have to be stress relieved after forming.
6. All nozzles shall be covered with blind flanges, bolts, nuts & gaskets.
7. Nozzles shall be stiffened with 2 nos. of gussets at 90º apart.
8. All the weldings has to be carried out by qualified welders.
9. Name plate & bracket shall be provided for the tank.
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Cleaning:
The tank has to be mechanically cleaned by buffing wheel, degreased
after hydraulic test according to the procedure given below.
Mechanic Cleaning:
All surfaces inside and outside having scales and foreign
materials have to be cleaned. This can be done by;
a. Scrubbing with metallic brush
b. Sand blasting (iron free sand) and the loose scales and
powders obtained from the above process shall be cleaned by
blowing or washing.
1. Degreasing:
This is to remove oil and grease. This can be achieved by
vapour phase degreasing using trichloroethylene.
2. Pickling: (for inside surface only)
This is carried out after mechanical cleaning and degreasing
operations to remove all the rusts and scales. Following are the
guidelines for carrying out the same.
a) Cleaning with water.
b) Pickling with a solution containing Hydrofluoric and nitric acid.
c) The composition of the pickling solution and duration of
pickling are adjusted after trial test on a sample piece to remove
uniformly less than 25 Micron thick materials. Mostly the
composition is 5% Hydrofluoric acid (by wt) + 15 to 20% Nitric
acid (by wt) + balance water at ambient temperature.
3. Passivation: (for inside surface only)
This is to be done after the pickling operation. A solution
containing 25% HNO3 (by vol) and 75% water (by vol) at ambient
temperature will be used for this purpose. Duration of the passivation
should be 2 hours minimum. Finally rinsing with de-mineralised
water is to be carried out.
Note: After the process, no mechanical cleaning should be attempted.
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a. The cleaned surface is to be checked by using a white filter paper.
Rubbing of the paper on the surface should not change the colour of
the paper.
b. By analyzing the final used water the quality of cleaning can be
checked. The rinse water should not have suspended particles
more than 20mg/m2 (based on surface area). The pH value of the
de-mineralised water must be between 6.5-7.5.
4. Drying:
The drying is done to remove water and is to be done by
purging with Nitrogen having dew point less than -25°C and free from
oil and grease (less than 10ppm) at 60°C till the moisture level at the
exit comes to the inlet concentration.
5. Sealing:
After drying, the tanks should be sealed so that ambient
moisture cannot enter inside. The tanks are to be pressurized to 50
m.bar (Kg) with dry N2 gas.
1.B. SPECIFICATION OF ELECTRICAL SYSTEMS
Specifications of Flame proof Electrical Equipments
Flame proof items shall have Ex ‘d’ classification with the gas group as per
IS/IEC 60079-0, IS/IEC 60079-1 with latest amendments with gas group
classification of IIA/IIB, Zone 1 and temperature classification shall be T4.
All the flame proof items shall be certificated by CIMFR.
If the flame proof enclosures are additionally required to be weather proof,
neoprene gaskets shall be provided to make the enclosure, dust and weather
proof providing a degree of protection IP65.
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1.B.1 Electric Motors
Power Supply 415±10% volts, 50 Hz±5%, Three phase
Method of starting /
Speed control Variable Voltage Variable Frequency (V3F) drives
Standards IS 325 (latest edition)
Type Squirrel Cage Induction Motor,
Efficiency Class IE2
Insulation class Class F
Ambient Temperature 45 deg. C
Enclosure TEFC, Ex ‘d’, IIA/IIC, T4 or better, Zone 1
IP 65
Duty S1
Application Pump
Motor Makes CGL, BBL, SIEMENS, ABB
VFD Makes ABB, Schneider, SIEMENS,
General Motors provided shall have adequate performance characteristics such as starting torque, pull out torque, GD2 value, speed torque curve, thermal withstanding curve, etc. for meeting the driving and starting duty of the motor.
1.B.2 Flameproof Control Panel/Junction Box
The flameproof Control panels shall be provided for local ON/OFF
near motor location and necessary flameproof MCCB/MCB/MPCB,
LED indication lamps, LOCAL/REMOTE selector switches etc shall be
provided.
All flame proof junction boxes shall be 2 nos. of earthing terminal at
outside and 1 no. of earthing point at inside.
The material of flame proof junction boxes shall be cast aluminium
alloy LM6, IP65, Group IIB, T4 or better, Zone 1.
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1.B.3 Power and Control Cables
All Power cables used for electrical connections shall be XLPE
insulated, armoured Copper cables 1.1 kV grade, XLPE insulated, and
overall sheathed, stranded copper conductor, flat steel strip/ wire
armoured cables conforming to IS: 7098/ Part I (with latest
amendments) and the cable shall bear ISI certification mark.
All control cables shall be FRLS 2.5 sq.mm, 1.1 kV grade, ISI marked,
PVC insulated single core, stranded copper conductor wire / cable
conforming to IS:694 (with latest amendments).
The power and control cables are to be routed through cable
trenches/trays and are to be clamped suitably.
Compression type cable glands suitable for cable sizes used shall be
provided on the motor terminal box. Flameproof double compression
type cable glands shall be provided for flameproof motors.
1.B.4 Non flame proof VFD Panel in Control Room
Floor mounted VFD panel consisting of heavy Duty VFD’s, multifunction meters, LED indication lamps, self illuminated push buttons, MCCBs, etc.
The VFD panel shall made of 2mm thick CRCA, powder coated, paint shade RAL7032/35, and Gland plate – 3.0 mm Thickness CRCA.
Earth busbar Size –Preferably '25 X 6 mm Cu' with nuts (double earthing).
VFD panel Base frame – ISMC 100 x 50 mm with Matt black.
The VFD shall have local HMI & Class “A” Input/EMI filter and breaking chopper shall be the integral part of VFD panel.
Panel cooling fans with louvers.
The VFD's are to monitored & controlled by HMI/SCADA/PLC systems for ON/OFF, TRIP interlock, Speed control, and monitoring of important electrical parameters such V, I, Power, Drive ready status, any alarm indications.
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The provision shall be made for VFD’s ON/OFF in from VFD panel as well as from motor location by selection of Local/ Remote.
All necessary power, control, communication cables between Motors, VFD panel, Local control at Motor location etc.
1.B.5 Earthing: • All electrical equipments such as Motors, panels, flame proof control panels, VFD’s, etc and shall be double earthed. Earthing shall be done using GI strips. The scope does not includes construction of earth pits and chambers, the scope includes that the earth strips are to be extended to electrical equipments from earth strip/ bench which is already available in the facility. • Static earthing shall be provided for earthing liquid tanks, liquid feed lines, etc., as per the standards/ requirements. All the liquid tanks, liquid pipe lines shall be static earthed.
1C. SPECIFICATION OF INSTRUMENTATION SYSTEMS
1.C.1 SMART ABSOLUTE PRESSURE TRANSMITTER
Sl. No Parameters Specification
1 Type SMART Absolute Pressure Transmitter
≥200 bar Gauge pressure transmitter can
also be quoted.
2 Measurement Range, Fluid
medium and Maximum
Allowable Working
Pressure
As per Table 1
3 Maximum Turndown Ratio 100:1
4 Output Two wire 4–20 mA with superimposed
Digital communication with HART
protocol.
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5 Power Supply 12 to 30 V DC.
6 Local Indication Minimum 4½ digits LCD – Local Alpha
Numeric Digital display in Engineering
units.
7 Safety Integrity Level
Standard (SIL)
Safety Instrumented System Certification as
per IEC 61508 standard, SIL 2 or above.
8 Zero & Span Adjustments Zero and Span are to be adjusted from the
Handheld HART Communicator and
provision for local adjustment to be set
anywhere within the range limits.
9 Failure mode alarms High alarm ≥ 21.0 mA
Low Alarm ≤ 3.6 mA
10 Accuracy
@ TD 8:1 for URL<200 Bar
and
@ TD 2.5:1 for URL>200 Bar
≤± 0.09% of Calibrated span
(including the effect of Terminal - Based
linearity, hysteresis & repeatability)
11 Ambient Temperature Effect
for 28°C variation
@ TD 8:1 for URL<300 Bar
and
@ TD 2.5:1 for URL>300 Bar
≤ ± 0.4 % span
12 Stability ≤± 0.2 % of URL for 10years
13 Power Supply Effect ≤± 0.005 % of Calibrated Span per Volt.
14 Over Pressure limit Over pressure limit of selected transmitters
shall be 1.5 times of URL
15 Nominal Operating
Temperature
280-350K
16 Response time ≤ 150 millisecond
17 Wetted Material As per Table 1
18 Fill Fluid As per Table 1
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19 Transient Protection 3kAcrest (8/20microsecond) as per IEEE
C62.41.2 , IEC61000-4-4& IEC61000-4-5.
20 Drain /vent port Not required.
21 Electrical Connection ½ " – 14 NPT (F) with SS plug for dust proof.
22 Transmitter Process
connection
½ " – 14 NPT (F) or suitable for the quoted
manifold
23 Housing Material Polyurethane covered aluminium with ½”-
14 NPT conduit entry.
24 External Grounding screw
assembly on transmitter
body
Required
25 Mounting Bracket Stainless Steel Bracket with SS fasteners,
bolts, nuts, washers and U-clamps suitable
for 2 inch pipe mounting.
26 Calibration Calibration shall be carried out at room
temperature in 5 steps ascending and 5
steps descending. Calibration certificate is to
be provided. Calibration shall be traceable
to National Standards.
27 Ingress Protection IP65/66/67
28 Manifold 3way manifold. The manifold shall be
manufactured by transmitter manufacturer
with catalogue part number and data sheets
or from one of the approved makes like
Parker, Swagelok, Anderson.
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1.C. 2. SMART DIFFERENTIAL PRESSURE TRANSMITTER
Sl.No Parameters Specification
1 Type SMART Differential Pressure Transmitter
2 Measurement
Range, Fluid
medium and
Maximum
Allowable Working
Pressure
As per Table 1
4 Turndown Ratio 100:1
5 Output Two wire 4–20 mA with superimposed Digital
communication HART protocol.
6 Power Supply 12 to 30 V DC.
7 Local Indication Minimum 4 ½ digit LCD- Local Alpha Numeric
Digital display in Engineering unit.
9 Safety Integrity
Level Standard (SIL)
Safety Instrumented System Certification as per IEC
61508 standard, SIL 2 or above.
10 Zero & Span
Adjustments
Zero and Span are to be adjusted from the
Handheld HART Communicator and provision for
local adjustment to be set anywhere within the range
limits.
11 Failure mode alarms High alarm ≥ 21.0 mA
Low Alarm ≤ 3.6 mA
12 Reference Accuracy
@ TD 5:1
≤ ±0.075%Span for URL above 100 mbar
≤ ± 0.1% span for URL below100 mbar
(including the effect of Terminal - based linearity,
hysteresis& repeatability).
13 Ambient
Temperature effect
for 280 C variation
@ TD 5:1
≤±0.4%Span for URL above 100 mbar
≤± 0.75% for URL below 100 mbar
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14 Stability ≤±0.2%URL for 5 years , for URL above 100 mbar
≤±0.2% URL for 1 year, for URL below 100 mar
15 Power Supply Effect ≤± 0.005 % of Calibrated Span per volt.
16 Mounting Position
Effect
Zero shifts can be calibrated out.
17 Static Pressure effect Span error: ≤ ± 0.2 % of span /70 bar for URL above
100 mbar.
Span error: ≤0.45 %span/70 bar for URL below 100
mbar
18 Maximum Static
pressure
As per Table 1
19 Over pressure limit Over pressure limit of selected transmitters should
be 1.25 times of URL (Upper range Limit) .
20 Nominal Operating
Temperature
280-350K
21 Response time ≤ 300 ms
22 Wetted Material As per Table 1
23 Fill Fluid As per Table 1
24 Transient Protection 3kAcrest(8/20microsecond) as per IEEE C62.41.2 ,
IEC61000-4-4& IEC61000-4-5.
25 Drain / vent port Not required.
26 Electrical
Connection
½ " – 14 NPT (F) with SS plug for dust proof.
27 Transmitter Process
Connection
½ " – 14 NPT (F) or suitable for the quoted manifold
28 Housing Material Polyurethane covered aluminium with 1/2-14NPT
Conduit entry.
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Table-1 List of Pressure Transmitter
Sl. No.
Tag No. Fluid
medium Type
Range (bar) Temperature
(K)
1. LPI701 GN2 AP 0-300 280-350
2. LPI701(S) GN2 AP 0-300 280-350
3. LPI702 GN2 AP 0-50 280-350
4. LPI702(S) GN2 AP 0-50 280-350
5. LPI703 GN2 AP 0-50 280-350
6. LP1704 GN2 AP 0-5 280-350
7. LP1704(S) GN2 AP 0-5 280-350
8. LPI705 GN2 AP 0-5 280-350
9. LPI 708 GN2 AP 0-10 280-350
10. LPI 708(S) GN2 AP 0-10 280-350
11. LPI 706 GN2 AP 0-5 280-350
12. LPIA01 IPA AP 0-5 280-350
13. LPIA02 IPA AP 0-10 280-350
14. LPIA03 IPA AP 0-10 280-350
29 External Grounding
screw assembly on
transmitter body
Required.
30 Mounting Bracket Stainless Steel Bracket with SS fasteners, bolts, nuts,
washers and U-clamps suitable for 2 inch pipe
mounting.
31 Calibration Calibration shall be carried out at room temperature
in 5 steps ascending and 5 steps descending.
Calibration certificate is to be provided. Calibration
shall be traceable to National Standards.
32 Ingress Protection IP65/66/67
33 Manifold 5 way manifold. The manifold shall be manufactured
by transmitter manufacturer with catalogue part
number and data sheets or from one of the approved
make Parker, Swagelok, Anderson.
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15. LPIA04 IPA AP 0-5 280-350
16. LPIA05 IPA AP 0-5 280-350
17. LPIA06 IPA AP 0-5 280-350
18. DP1 IPA DP 0-500mbar, LP=5bar 280-350
19. DP1(S) IPA DP 0-500mbar, LP=5bar 280-350
20. DP2 IPA DP 0-2 bar, LP=5 bar 280-350
21. DP2(S) IPA DP 0-2 bar, LP=5 bar 280-350
22. DP3 IPA DP 0-500mbar, LP=2 bar 280-350
23. DP3(S) IPA DP 0-500mbar, LP=3 bar 280-350
(S) indicates spare measurement
1.C.3a.SPECIFICATION OF 3 way MANIFOLD
1 Type : 3 way manifold
2 Material : 316 SS
3 Packing material : PTFE
4 Seat type : Integral
5 Instrument Connection : Suitable for quoted transmitter interface
6 Process connection : ½ inch-14 NPTF
7 Maximum Operating
Pressure
: 400 bar for pressure transmitters up to
250bar
8 Operating Temperature : 280-350K
9 Hydro Testing at factory : To be carried out at 1.5 times the maximum
operating pressure for all the manifolds and
certificate to be provided
10 Material Test certificate : To be provided
11 Mounting Bolts : To be supplied with SS material.
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1.C.3b. SPECIFICATION OF 5 WAY MANIFOLD
Along with offer, the vendor shall supply the detailed catalogue and the selected
model matrix for pressure transmitter and manifold. The dimensional drawing for
manifold shall also be provided.
1.C.4 TEMPERATURE TRANSMITTER
Inputs : a. 2/3/4 wire Pt 100 IEC
: b. 2/3/4 wire Pt 500 IEC
Output Signal : Two-wire, 4-20mA with superimposed digital communication (HART protocol)
Power Supply : 12 to 42 VDC
4-20 mA D/A accuracy
: ≤ ± 0.03% of span
CJC accuracy for : ±0.25 degC
1 Type : 5 way manifold
2 Material : 316SS
3 Packing material : PTFE
4 Seat type : Integral
5 Instrument Connection : Suitable for quoted transmitter interface
6 Process connection : ½ inch-14 NPTF
7 Maximum Operating
Pressure
: 400 bar for pressure transmitters up to
250bar
8 Operating Temperature : 280-350K
9 Hydro Testing at factory : To be carried out at 1.5 times the maximum
operating pressure for all the manifolds and
certificate to be provided
10 Material Test certificate : To be provided
11 Mounting Bolts : To be supplied with SS material.
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T/C
Ambient Temp effect for 10 °C variation in temperature
: RTD (IEC: Pt500, Pt100): 0.04ohm
Stability 0.05%URL for 5 years
Indication : Minimum 4½ or 5 digit LCD indicator
Zero and Span Adjustment
: By Hand-Held Terminal or Local adjustment.
Temperature Limits : Operation: 280-350K
: Storage : 280-350K
Sensor Failure : In case of sensor or circuit failure, theself diagnostics to drive the output to 3.9 or to 21.0mA,user selectable.
Humidity Limits : 10 to 100% RH (non condensing)
Turn-on Time : ≤ 10 seconds
Update Time : ≤ 0.5 seconds
Damping : 0 to 30 sec (adjustable)
Power Supply Effect
: ≤ ± 0.005% of calibrated span per volt.
EMI Effect : To be designed to comply with IEC standards
Alarm : As per NAMUR standards.
Configuration : To be done by an Hand- Held terminal (HART protocol) or locally using switches.
Electrical connection : ½-14 NPT
Material of Construction
: Painted copper aluminium housing, with Buna N 0-rings on cover
Ingress Protection : IP65/66/67
Accessories : Mounting bracket to be supplied to mount on 2” pipe
1.C.5 RTD PROBES
Measurement range: 280-350K
Time constant: ≤3 s
Material of sheath: SS 316
Insulation resistance: >100 MΩ at 50 Vdc
Sensitivity: 0.00385 Ω/Ω/C
Immersion length: 40mm
Stability of R (0C): 500 Ω Nominal ± 0.001 Ω
Max. Pressure: 15 bar
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Max. Flow rate: 20 m/s (perpendicular to the sensor)
Suitable mounting interface for mounting is to be provided
Calibration certificate for the measurement range is to be provided
Table-2 List of Temperature Transmitter
Sl. No.
Tag No. Range (K)
1 LTI701
280-350
2 LTI702
3 LTCA01
4 LTCA02
5 LTCA03
6 LTCA03 (S)
Table-2a List of RTD Probes
Sl. No.
Tag No. Range (K)
1 LTI701 280-350K
Medium GN2
2 LTI702
3 LTI701(S)
(S) indicates spare measurement
RTD Probes to be supplied by vendor but surface RTD (Test article measurement)
will be under department scope. But, all temperature transmitters to be supplied by
vendor.
1.C.6 MASS FLOW METER
Flow tube :
Type : Coriolis Mass flow
Tag No : As per Table-3
Fluid Medium : IPA
Maximum Operating pressure : 10bar
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Operating Flow range : 0-5 kg/s
Line size (NB) : 2”
End Connection : RF Flanged ANSI B16.5, #150 class
flange rating
Process temperature : 280 to 350 K
Mass flow accuracy (Including linearity ,
Repeatability & zero stability)
@ Max. flow & Min. flow : ≤± 0.15% of Reading
Pressure Drop
@ Max. flow & Min. flow : < 0.05Mpa
Temperature accuracy : ± 1°C ± 0.5% of rate in °C
Materials of construction
Flow Tube & Flange
Housing
: SS 304L/SS316L
SS 304/SS316 Transmitter
Transmitter Output : 1. One active 4-20 mA output to represent Mass Flow with HART communication
2. One passive 4-20 mA output to
represent Mass / temperature /
density
3. One active pulse output for mass
flow rate
Power supply : 24 V DC ±10%
Field mount housing : Epoxy painted cast Al housing
Housing protection : NEMA 4X (IP67)
Flow Transmitter Mounting : Remote/Integral mount (For remote
mount: mounting kit to be provided,
interconnecting cable to be supplied)
Local display : LCD display, Flow rate/ Total in
Engineering unit.
Programming : Through Front Panel Key Pad &
HART Communicator
The party shall provide the following along with the quote
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Catalogue, Drawing & Specifications:
The party shall provide detailed catalogue showing part numbers and
options selected in their quotation.
The party shall provide with dimensional drawing of quoted flow meter.
The quote shall indicate the inaccuracy of flow meter including Non-
linearity, Repeatability, Long term stability & Zero stability for the minimum
and maximum flow rates.
Flow meter Sizing Sheet
The party shall provide detailed sizing sheet with Pressure drop, Velocity &
Accuracy for operating flow range.
During procurement and supply phase, the vendor shall provide with
Calibration Certificate
Calibration certificate of fully assembled flow meter from National
Accredited Laboratory shall be provided.
Calibration shall be carried out at minimum 5 points of required flow range,
with water or equivalent medium, preferably water.
Accuracy of calibration rig to be provided.
The accuracy change due to calibration medium other than water shall be
provided.
The vendor shall dispatch the items, only after the approval of calibration
certificates.
Table-3 List of Flow Meter
Sl. No.
Tag No. Fluid medium Mass flow rate Temperature (K)
1 LFQA01
IPA 5 kg/s 280-350
2 LFQA02
IPA 5 kg/s 280-350
3 LFQA01(S)
IPA 5 kg/s 280-350
(S) indicates Spare measurement.
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1.C.7 HART COMPATIBLE HAND HELD COMMUNICATOR FOR
PROGRAMMING THE TRANSMITTERS.
HART communicator suitable for communicating with all quoted pressure,
temperature, Guided Wave level & flow transmitters. The communicator should be
able to communicate all device specific and generic commands. The required
updated versions of DDs shall be loaded.
Note: The party shall provide detailed catalogue along with offer. Along with the
supply of items, the party shall provide test certificates.
1.C.8 SOLENOID VALVE Valve Body
Type: Three way, Normally closed
Body material : SS 316
Housing : Die cast Aluminium epoxy painted
Stem: SS 316/ SS304
Seat: Viton
End connection: Threaded female NPT conforming to ANSI-B1.20.1. 1/4"
NPT (F)
Mounting altitude: Any altitude without affecting their operation.
Orifice Size: <3 mm
Solenoid
Power supply : 24 VDC / 300 mA (max)
Solenoid coil: Suitable for continuous energization.
Enclosure: IP 65/66/67
Coil insulation: Class H as defined in IS: 1271.
Coil pick up voltage: Between 50 to 70% of normal supply voltage.
Coil drop up voltage: Between 30% to 50% of nominal supply voltage.
Coil temperature rise: Not to exceed 70°C.
Double coil
Response Time : Less than 100 ms.
Conduit connection: Enclosure shall have 1/2” NPT (F) connection for
power Supply cable.
Mode of operation: Direct operated
Manual operation : Provision to open the valve using Lever
Freewheeling Diode : Two diode in series to be provided (polarity should
be indicated in the supply coil side)
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Process condition
Fluid: Given in table-4
Operating Pressure: Min. 2 bar, Max. 10 bar, Nominal: 7 bar
Service Life : 50,000 cycles
Operating Temperature: 280-350K
Relative humidity: up to 95%
The party shall provide the following along with the quote.
Catalogue, Drawing & Specifications:
The party shall provide detailed catalogue showing part numbers and
options selected in their quotation.
The party shall provide with dimensional drawing of quoted solenoid.
(s) indicates spare
1.C.9 JUNCTION BOX
1. Enclosure
All Junction Box shall be weather proof & explosive proof.
The degree of ingress protection shall be IP65/66/67.
The equipment shall be suitable for operating in humid & corrosive
atmosphere
Junction box shall have housing of cast aluminium LM6 alloy
All Junction Box shall be provided with neoprene gaskets.
All accessories like nut, bolts, washers etc shall be made of stainless steel
SS- 304.
Sl. NO.
Tag No. Fluid
Medium
Nominal Size
(metric)
MAWP (MPA)
Pressure rating class
Normal Position
Response time (sec)
Working temp. range
(K)
1 LVP709 GN2 DN100 1.43 150 Closed 2 280-350
3 LVP710 GN2 DN40 1.43 150 Open 1 280-350
5 LVP701 GN2 DN15 1.43 150 Closed 1 280-350
7 LVPA02 IPA DN50 1.43 150 Closed 2 280-350
8 LVPA03 IPA DN50 1.43 150 Closed 2 280-350
9 LVPA04(S) IPA DN50 1.43 150 Closed 2 280-350
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Conduit and cable entry- Side & Bottom Entry
Door of JB- Hinged with proper locking arrangement to avoid entry of
dust and moisture
Ambient temperature-50 deg C
Ambient humidity-0-100 % RH
Earthing : Two numbers of Earthing bolts for JB Earthing.
Junction box size shall be of 300 x 300 x 165mmdimensions. The exact
dimension shall be finalized during Detailed Engineering.
2. Terminal blocks
Terminals shall be shrouded and shall be numbered as per the wiring
diagram. Minimum rating of the terminal block shall be 5 Amps.
For Individual shielded multipair cables a separate terminal shall be
provided for each shield drain wire.
Terminal Strip- screw-less cage clamp type capable of terminating 1
sq.mm and 1.5 sq mm cables
3. Name plate
Aluminium anodized nameplate indicating the equipment to be
controlled shall be provided on each local Junction Box. The particulars
of the plate will be supplied to the vendor. Nameplate shall be fixed by
screws and not pasted.
The letter shall be engraved in black on white background.
Certificate numbering date and gas group classification must be indicated
on the manufacturer’s nameplate on each junction box.
4. Mounting
Junction Box shall have 4 lugs for fixing on wall or fabricated steel support.
The lugs shall be offset so that the rear of the unit stays away from the
surface by at least 5mm. Two of the holes shall be round and the other two
oblong to facilitate correct positioning. All screws, nuts and studs etc. shall
be of electro galvanized or zinc passivated type.
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5. Painting
The enclosure shall be treated & prepared for painting with two coats of
Dark admiralty grey shade 632 of IS-5 epoxy paint (Both inside and
outside)
The party shall provide the following along with the quote
Catalogue, Drawing & Specifications:
The party shall provide detailed catalogue & dimensional drawing of quoted
junction box.
Dimensional drawing shall indicate pneumatic tubing entry, inside header
and cable entry provisions
During Detailed engineering, the exact number of cable entries shall be
decided and the final drawing shall be approved by Department before
fabrication.
1.C.10 PVC CABLE
CONSTRUCTION:
64 Core (32x 2core) PVC Cable (Un-Armoured)-FRLS Type
18AWG (19/0.25mm) Annealed tinned high conductivity copper conductor,
insulated with polyethylene, 2 cores of Red and Black twisted to form a pair,
melinex taped, mylar backed aluminium taped with a drain wire of size 7/0.31mm
Annealed tinned copper, melinex tapped, PVC sheathed, such 32 groups laid up,
melinex tapped, overall sheathed with FRLS PVC and Blue in colour.
2 Core PVC Cable (Armoured) – FRLS Type
One pair of 19/0.25 mm (18 AWG) annealed tinned copper conductor,
polyethylene insulated, cores colour coded, melinex taped, mylar backed
aluminium taped with a drain of size 19/0.25 mm Annealed tinned copper, melinex
tapped, PVC sheathed steel round GI wire armoured and overall sheathed with
FRLS PVC and Blue in colour.
4 Core PVC Cable (Armoured) – FRLS Type
2 pairs of 7/0.31mm (20 AWG) annealed tinned copper conductor,
polyethylene insulated, cores colour coded, both pairs laid up to form a group,
melinex taped, mylar backed aluminium taped with a drain of size 7/0.31mm
Annealed tinned copper, melinex tapped, PVC sheathed, steel round GI wire
armoured and overall sheathed with FRLS PVC and Blue in colour.
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2 Core PVC Cable (Armoured) – FRLS Type
One pair of 7/0.31mm (20 AWG) annealed tinned copper conductor,
polyethylene insulated, cores colour coded, melinex taped, mylar backed
aluminium taped with a drain of size 7/0.31mm Annealed tinned copper, melinex
tapped, PVC sheathed steel round GI wire armoured and overall sheathed with
FRLS PVC and Blue in colour.
DETAILED SPECIFICATIONS:
1. Voltage grade : 300 V
2. Operating temperature : 15 Deg.C to 50 Deg.C
3. Conductor :
a) Material : Annealed Tinned copper as per IS:8130
b) Size of the conductor : 20AWG (7/0.31mm)
18AWG (19/0.25mm)
4. Insulation
a) Material : solid polyethylene type-03of BS6234
b) Thickness (Nom.) : 0.40 mm
c) Pair colors : Red, Black (Twisted)
d) No. of twists/mtr : 30 (Min)
e) Dia. over insulation (Nom.) : 1.75 mm
5. Screening over group
a) Tapping before and after : Thickness of melinex tape to be 0.025mm
(100% screening Coverage, min-20% overlap)
b) Screening
i) Material : Aluminium mylar tape
ii) Thickness : 0.044mm
iii) Coverage and overlap : 100% Coverage and 35% overlap
iv) Drain wire : 7/0.31mm Annealed tinned copper
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6. Inner sheath
a) Material : PVC type ST2 of IS:5831with FRLS properties
b) Thickness (Nom.) : 0.65 mm
c) Colour : Black
7. Outer sheath
a) Material : PVC type ST2 of IS:5831with FRLS properties
b) Thickness (Nom.) : 2.2 mm (96 & 64 Core)
2.0 mm (16,4 & 2 Core)
c) Colour : Blue
8. a) Insulation elongation : 300%
b) Sheath elongation : 150%
c) Insulation T.S : 100 Kg/cm2
d) Sheath T.S : 125 Kg/cm2
9. a) Approx. overall diameter : 96 Core : 46.0 mm
64 Core : 46.0 mm
16 Core : 23.0 mm
4 Core : 16.0 mm
2 Core : 10.0 mm
b) Tolerance : ± 2mm
10. Electrical parameters
a) Conductor resistance at 20
deg.C
: 20 AWG: 40.0 Ohms/Km
18AWG: ≤21.5 ohm/Km
b) Min. Insulation resistance of
finished cable at Room
Temperature
: 5000 Mohms-Km
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c) Max. Mutual capacitance : 75.00 pF/m at 0.8/1.0KHz
d) Max. capacitance core to screen
at 0.8/1.0KHz
: 400 pF/m
e) Max. drain wire resistance (with
screen contact)
: 37 ohms/Km
f) Inductance : 20 AWG: < 650 H/Km
18AWG: < 1000H/Km
g) L/R Ratio : 20 AWG: < 25 H/ohm
18AWG:< 40H/ohm
h) Static noise : better than 60dB
i) Characteristic impedance
(typical)
: 20 AWG: 450 ohm ± 15%
18AWG:350 ohm 15%
HV test
i) Conductor to conductor : 1 KV for 1 minute
ii) Conductor to screen :
11. FRLS Tests
1. Min Oxygen Index when tested
as per ASTM D2863
: 29%
2. Min Temperature Index when
tested as per ASTM D2863
: 250 Deg. C
3. Max Smoke Density rating
when tested as per ASTM
D2843
: 60%
4. Max Acid gas generation when
tested as per IEC 754 (I)
: 20%
5. Flammability test as per IEEE
383,IEC 332-III category-C and
SS424 1475 CLF3
: Shall meet the requirement
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12. General : Cable should be Anti-Rodent and Anti-
termite type
13. Cable mark : a. The cable group number (1-16) shall be
printed on the cable at 0.5m interval.
b. The cable type shall be embossed /
printed on the outer sheath at 1.0m
interval.
14. Length marking : At every meter on outer sheath.
15. Drum lengths :
i) Standard Continuous length : 96 & 64 Core: 500 meters
16,4 & 2 Core: 1000 meters
ii) Tolerance : ±5%
Applicable only for Armoured Cables
16. Armouring
a) Material : Galvanized Steel round wire
b) Size : 1.4 mm dia
General Specifications:
1. Wherever PVC is specified virgin PVC should be used.
2. All cables should have ‘anti-rodent’ type outer sheath and should be
immune to termite attack. It is required to have these protections by
addition of chemicals to outer sheath.
3. Cable testing as stipulated in section 1 shall be conducted and
necessary conformity certificate should be supplied by the
manufacturer.
4. Thermal aging test certificate to be provided by manufacturer for each
type of cable.
5. Cable should be manufactured relevant to the following standards.
a. Copper conductor : IS 8130 – 1984
b. Poly Ethylene (PE) insulation : BS 6234
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c. PVC insulation : IS 5831.
d. FRLS properties : ASTM D2863, IEC 754(I),
IEC 332-III category-C &
SS424 1475 CLF3
6. Proper packing material to be used during laying (manufacturing) in
order that the finished sheathed cable cross section is circular with a
tolerance of ±5% of dia.
7. Cable should have proper laying to maintain circularity and tight
packing with outer sheath shall be ensured.
8. Cable drum should withstand transportation and handling.
9. The drums shall be proofed against attack by white ant or termite,
conforming to IS:10418:1982
Cable Testing
The following tests as per applicable IS/BS standard shall be conducted in
the presence of Department engineer and test certificate to be provided.
a) Conductor resistance test
b) Cold bend test
c) Insulation resistance test
d) High voltage test
e) Mutual capacitance test
f) FRLS tests:
i. Min Oxygen Index test as per ASTM D2863
ii. Min Temperature Index test as per ASTM D2863
iii. Max Smoke Density rating test as per ASTM D2843
iv. Max Acid gas generation test as per IEC 754 (I)
v. Flammability test as per IEEE 383,IEC 332-III and SS424
1475 CLF3
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Note:
1. The vendor shall provide detailed catalogue along with offer
2. The vendor shall provide sample piece during detailed engineering from the
manufacturer.
3. The tests shall be carried out in the presence of Department Engineer.
4. The vendor shall provide test certificate before dispatch of items. The vendor
shall dispatch the item only after clearance of test certificates by Department.
18/20 AWG Single core PTFE wire
1. C.11 18 AWG SINGLE CORE PTFE WIRES
Inner conductor : Multi Stranded silver plated copper wire of size
AWG 18/19/0.25mm.
Standard : MIL-W-16878 (or) JSS 51034
Core insulation : PTFE tape wrapped and fused
Insulation thickness : 0.25 0.05 mm
Conductor dia (Nominal) : 1.27 0.03 mm
Diameter of core including
insulation
: 1.87 0.1 mm
Colour : To be decided during Detailed Engineering
Max. Resistance of the
conductor at 20 O C
: 18.99/Km
Roll : 100m 10%continuous per drum
1.C.12 20 AWG SINGLE CORE PTFE WIRES
Inner conductor : Multi Stranded silver plated copper wire of size
AWG 20/19/0.2mm.
Standard : MIL-W-16878 (or) JSS 51034
Core insulation : PTFE tape wrapped and fused
Insulation thickness : 0.25 0.05 mm
Conductor dia (Nominal) : 1.02 0.03 mm
Diameter of core including
insulation
: 1.57 0.1 mm
Colour : To be decided during Detailed Engineering
Max. Resistance of the
conductor at 20 O C
: 32.8/Km
Roll : 100m 10%continuous per drum
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TEST DETAILS ON EACH OF THE ABOVE MENTIONED CABLES AS PER
JSS: 51034 STANDARDS
The following tests are required to be carried out at manufacturer’s site.
NAME OF THE TEST EXPECTED REQUIREMENT
1. Dimensional check : As per standard
2. Concentricity of Insulation : Greater than 70%
3. Spark test : 3.4 KV for 1 sec
4. Conductor Resistance : As per standard
5. Dielectric withstanding voltage : 2.0KV for 1 minute
6. Insulation Resistance : 1500M/km.Min
7. Silver coating thickness over conductor : 1 micron Min
8. Conductor Elongation : 10% Min
9. Insulation tensile strength : 21 106 N/m2 Min
10. Insulation Elongation : Greater than150% Min
11. Cold Bend : -65° C for 4 Hours
12. Heat resistance : 290C for 96 Hours
13. Wrap Back (307C for 2 Hours) : No cracks. No dielectric
Break down.
14. Flammability :i) Wire shall cease to burn less than 10 sec.
ii) Total length burnt or
charred not exceed 75 mm
ON FINISHED CABLE
1. Shielded coverage : 90%
2. Dielectric withstanding voltage between : 2 KV for 1 minute core and shield
Note: 1. The party shall provide detailed catalogue along with offer. 2. The vendor shall provide sample piece during detailed engineering from the
manufacturer. 3. The vendor shall provide test certificate before dispatch of items. The vendor
shall dispatch the item only after clearance of test certificates by Department.
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1.C.13 CABLE TRAYS
Perforated Cable Tray:
Type : Perforated type cable tray
Material : Mild Steel As per IS: 2062 / 1079
Finish : Hot dip galvanized, Self-color.
Galvanizing : As per IS: 2629 / 4759
Length : Standard length of tray is 2500 / 3000mm
Loading : As per NEMA standard
Size : As per table
Table
WIDTH (mm) HEIGHT (mm) THICK (mm)
50 25 1.6
100 25 2.0
300 50 2.0
Note: Accessories like cross, Vertical bend, Reducer, Horizontal Tee, Coupler
plates, necessary Bolts & Nuts to be quoted as 1 lot.
Ladder type Cable Tray:
Type : Ladder
Material : Mild Steel As per IS: 2062 / 1079
Finish : Hot dip galvanized, Self-color.
Galvanizing : As per IS: 2629 / 4759
Length : Standard length of tray is 2500 / 3000mm
Rung Spacing : 250 mm
Loading : As per NEMA standard
WIDTH (mm) HEIGHT (mm) THICK (mm)
300 100 2.5
Operating temperature : 60 °C maximum
Humidity : Up to 95% RH
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Note:
The Accessories like cross, Vertical bend, Reducer, Horizontal Tee,
Coupler plates, necessary Bolts & Nuts shall be quoted.
The vendor shall provide detailed catalogue along with offer
1.C.14 STRUCTURAL STEEL MATERIALS
1. Material : Structural steel includes steel sections,
L angles, Plates, steel pipes chequered & Plain
plates
2. Material Governing
standard
: IS 2062 (GRADE-A)
3. Dimensions governing
standard
: IS 808 & IS 1161
4. Certificates : Test certificates showing heat number,
physical and chemical properties of the
items in conformance to relevant standard
shall be sent along with dispatch documents.
1.C.15 SPECIFICATIONS OF ISOLATORS
ISOLATORS FOR PRESSURE AND TEMPERATURE MEASUREMENTS Type: Isolators HART communication interface possible through both 4-20 mA outputs. 1. Input (Intrinsically Safe)
Input signal : 4 mA - 20 mA Voltage at 20 mA : 16V min
2. Outputs (Not Intrinsically Safe) Output voltage : 2-10V Number of outputs : 1 Output resistance : 500ohm Ripple : <=25mV
3. Power Supply: Supply voltage : 20V- 35V DC Connection type : Power rail and terminal
4. Details of certificate of conformity Group, Category, ignition protection Method:
: ATEX II 2 G EExiaIIC T6 Voltage (Uo) : <28VDC Current (Io) : <100 mA
5. Transfer Characteristics Transfer error :<=0.1%
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6. Galvanic Isolation Between
: Input & Output. : Input & Power supply : Output & Power supply.
7. General Operating temperature : 15°C to 50°C Power supply feed provision : Through power rails/Back plane Mounting : DIN rail (35 mm)
ISOLATOR FOR E/P VALVE STATUS 1. Input
Type : Proximity/Relay. No. of channel : 2 Reverse mode : To be provided LED indication : Relay output & power supply Connections Type : Terminals Lead monitoring : Required
2. Output (not intrinsically safe) Connection type : Terminals Output I & II : signal; relay Minimum switching current : ≥2 mA/24V DC Energized/De-energized delay : approx. 20 ms / approx. 20 ms Mechanical Life : 10^7 switching cycles
3. Power supply Connection type : Power rail and terminals Rated operational voltage : 20…30 VDC
4. Details of certificate of conformity Group, Category, ignition protection Method
: ATEX II 2 G EExiaIIC T6 Voltage (Uo) : 10.5 V Current (Io) : 14 mA
5. Transfer characteristics Switching frequency : ≥10 Hz 6. Galvanic Isolation Between
: Input & Output. : Input & Power supply : Output & Power supply.
7. General Operating temperature : 15°C to 60°C Power supply feed provision : Through power rails/Back plane Mounting : DIN rail (35mm)
ACCESSORIES The party shall quote for all required accessories such as power rails, power feed modules, Din rail, mounting kit, Backplane etc.
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Note: The party shall provide detailed catalogue along with offer. Along with the supply
of items, the party shall provide test certificates. The isolators shall undergo
functional test, linearity check etc at Department site after supply. After passing the
test as per specification only, the isolators shall be accepted by Department.
1.C.16 SPECIFICATION FOR ELECTROMECHANICAL RELAY
Technical data:
Coil side:
Nominal i/p voltage : 24 VDC
Nominal i/p current : 18 mA
Typical response time : 8 ms
Typical release time : 10 ms
Protective circuit : Reverse polarity diode and
Free wheeling diode provision.
Contact side:
Contact type : DPDT
Contact material : AgNi
Maximum switching voltage : 250VAC/DC
Minimum switching voltage : 5VAC/DC (at 10 mA)
Minimum switching current :10 mA
Limiting continuous current : 6 A
Interrupting rating max : 140 W (at 24 VDC)
General data:
Test voltage relay winding/relay contact : 4 KVAC (50 Hz, 1min)
Test voltage PDT/PDT : 2.5 KVAC (50 Hz, 1min)
Operating temperature : 15 to 60 º C
Mechanical life service : 3*107 cycles
Standards/Regulations : IEC 60664, EN 50178, IEC 62103
Indication : LED for indicating Command ON
Connection data:
Connection method : Screw connection
Conductor cross section solid max : 2.5 mm2
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Note: 1. The party shall provide detailed catalogue along with offer. 2. Along with the supply of items, the party shall provide test certificates. The
relays shall undergo functional test at Department site after supply. After
passing the test as per specification only, the relays shall be accepted by
Department.
1.C.17 SPECIFICATIONS OF SWITCHED MODE POWER SUPPLIES
(Low ripple) Configuration:
Dual redundant configuration with Din rail mountable diode ‘OR’ ing unit.
Each unit consists of two numbers of single power supply and one diode ‘OR’ing
module.
Input:
Voltage : 230V AC
Frequency : 50 Hz
Power factor Correction : ≥ 0.9 at 230V AC input
Output:
Voltage : 24V ±10%
Voltage setting accuracy : ±1%
Current rating : 10 A
Ripple : 5 mVrms
Efficiency : 85%
Output voltage setting : Through front panel
Status output:
Power supply O.K. signal : Potential free contact
LED Indications:
For output voltage : To be provided
For output low voltage : To be provided
Protections:
Short circuit protection : To be provided
Over voltage protection : To be provided
General:
Operating temperature range : 15˚ to 55˚C
Cooling : Natural air cooling
Parallel Operation : Set in single or parallel mode
Mounting : DIN rail mountable
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Connection type : Screw connection
Isolation Voltage : Input to output 3KVAC for 1 min.
Compatibility to EMI : As per applicable standards
Note:
The party shall provide detailed catalogue along with offer.
The power supply shall undergo load regulation test, ripple test, stability test and
line regulation test. After passing the test as per specification only, the power
supply and shall be accepted by Department.
1.C.18 Multi-pin CONNECTORS
Male and Female Contacts
Type : Crimp
Contact Material : Copper alloy-hard gold plated over Ni
alloy Gold plating thickness: 2μm Ni
thickness: 3μm
Contact size : 18 AWG and 20AWG
Working Current : 10 A
Working voltage : 600 V
Insulation resistance : ≥ 100 M ohm
Contact resistance : 3milli Ohm
Crimp connection
- Stripping length : 8.0 mm
2. Inserts:
No. of Poles : 72(3sets including spare)/42 (2 sets
including spare)
Rated Voltage to UL/CSA : 600 V
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Rated current : 10 A
Rated impulse withstand voltage : 4 kV
Pollution severity : 3(Conductive pollution, or dry,
non-conductive pollution that is
liable to be rendered conductive
thru condensation)
Insulation resistance : ≥ 1010 ohm
Material : Glass fiber reinforced Poly
Carbonate
Temperature Range : 15 oC …. +50 oC
Flammability to UL 94 : V0
Mechanical service life : ≥ 500 mating cycles
3. Hoods
Materials : Die-Cast Aluminium
Surface : Powder coated RAL 7037(Grey)
Flammability to UL 94 : V0
Cable entry : Bottom/Top
Cable entry dia : M32
Protection : IP65
4. Base Housing (bulk head)
Material : Die-Cast Aluminium
Surface : Powder coated RAL 7037(Grey)
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Flammability to UL 94 : V0
Locking Mechanism : Double latch
Locking material : Stainless Steel
Cable entry dia : M32
Protection : IP65
5. Standards & Certifications
1. Certification : UL, CSA or equivlent
2. Standard : DIN EN 60 664.1 DIN EN 61 984
6. Cable Entry Gland
1. With suitable cable gland/clamp with strain relief features
2. Material/Colour : Polyamide 6/RAL 7035
3. Temperature range : 15C…50C
4. Class of protection : IP 65
5. The thread shall suit to the cable entry points at the Hood and Housing.
7. Sealing Plug
1. Material/Colour : Polyamide 6/RAL 7035
2. Temperature range : 15C to 50C
3. Size : M32
4. The thread shall suit to the cable entry points at the Hood and Housing
Note:
The party shall provide detailed catalogue along with offer indicating the part
number of items and specifications.
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1.C.19 INSTRUMENTATION DOUBLE RACK
Controller, I/O modules, Programming, SCADA and Data storage node and
relevant devices shall be housed in standard instrumentation rack. The number
of racks required and their general assembly shall be decided at the time of
detailed engineering.
1.C.19.1 SPECIFICATION
1. Dimension
Height - 42U Width(1200mm) & Depth(800mm)
2. Standard : Conforms to DIN 41494 & EIA 310
3. 100 mm Height Base Frame for additional clearance for cable entry.
4. Frameworks: Self standing type 2-2.5 mm CRC steel plates
5. Lockable front door made of toughened tinted glass
6. Lockable rear steel door with venting options
7. Side panels with slam latches and vented top cover
8. Cooling fans and lighting shall be provided.
9. Panel lighting fluorescent type with on/off switch and interlock with
door.
10. Earthing continuity kit shall be provided.
11. Paint color shall be decided during detailed engineering
12. Cables entry / access: From the bottom
13. All accessories (bolts / anchor fasteners/ ‘L’angles) required for fixing of
all the equipments shall be provided.
14. Service Power supply socket of 230V, 50 Hz
15. Panel meters with following indications shall be provided:
Cabinet Temperature
Current
Voltage
16. Make : Rittal / President System
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1.C.19.2 WIRING
1. Wiring shall comply with the applicable IEC codes. Wiring for different
voltage signals or different functions shall be terminated separately on
dedicated terminal strips/ raceways with color coding.
2. Separate color coding to be followed for utility power (fan, temperature
monitor) and process power (I/O modules, processor).
3. Wiring shall be accomplished with flexible stranded tinned copper wires
sized 18/20 AWG, PTFE cable in compliance with the applicable codes.
4. Wires shall be housed in plastic raceways of suitable dimensions to
accommodate system cables, I/O signal cables etc.
5. The routing shall be neat and have elegant look.
6. Electrical power distribution shall be done as per requirement for system
cabinet and cables shall be routed through separate raceways.
7. Control system cabinet shall have local MCBs for isolating different loads.
8. Power supply positioning in the cabinet shall be suitably placed to avoid
electromagnetic interference to electronic components.
9. The cabinet shall be supplied with all necessary hardware & accessories
and with complete wiring.
10. Wiring and workmanship shall be of good quality.
11. Cable glands suitable for I/O cables are included in the vendor’s scope.
The cable glands shall be of polyimide material.
12. All I/O cables to be terminated at lock type plug-in multipin connector
and to be mounted at the system cabinet.
13. The panel shall have at least 20% extra terminals for future use.
14. Terminations, cables, wiring, components shall be properly tagged with
ferruling at both sides of the termination.
15. Terminal strips shall be of adequate size min 1.5 mm2.
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1.C.20 SPECIFICATION OF 3 SEGMENT CONSOLE
The console shall have work surface with a closed equipment cabinet at back to accommodate equipments like power supply, terminal blocks and a box on the work surface to accommodate intercommunication equipments and switches. (Intercommunication equipments will be supplied by Department and details will be provided during detailed engineering)
The consoles shall be provided with aesthetically pleasing curved end panels. The layout of console shall have curved design.
Console should be designed in accordance with the ergonomics standards and accepted human factors guidelines of ISO 11064.
Work surface: The work surface includes a flat work area, PC mounting provision, a box for mounting switches and inter communication equipments.
The work surface shall be premium acrylic solid surface material with glossy finish. Both ends shall be thermoformed and create continuous water fall edge to increase the aesthetics of console.
The thickness of acrylic solid surface shall be of 12mm min. This surface shall be mounted on Medium Density Fibre (MDF) board of minimum 25mm thick.
Surface to floor height shall be of 750 mm with 50mm height adjustable floor leveling bolts.
Work surface depth shall be of 1000mm. The width of each console segment shall be of 1100mm.
The work surface shall be a single unit, seamlessly integrated over the whole cluster of segments. Work surface shall be continuous at joints of segments.
The acrylic work surface shall have steel frame underneath for support and must be rigidly fixed to the cabinet structure to form an integral unit.
Work surface front edge shall be inbuilt ergonomic sloped with bull nose front edge. T-mould, PVC edge or vinyl edge trims are not acceptable.
The bearable static load shall be of 50kg. Sliding keyboard tray under the work surface shall be with ball
bearing operation. Friction or roller type slides are not acceptable.
The work surface of console shall support articulated arms for mounting the TFT/LCD flat monitors (diagonal size: 24 inches) with PAN (180°) & TILT (± 20°) adjustment mechanism.
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A box shall be provided with a removable panel for mounting illumination switches, Authorization keys and intercommunication equipments. Easy human access to remove and re-fix the box shall be possible.
The rear view of the console shall be aesthetically pleasing and shall be provided with slat wall.
Cabinet: The console shall be provided with a rigid structured cabinet
back of the work surface, heavy-duty to accommodate power supply, terminal blocks and other necessary equipments.
The rear compartment of console shall have holed profiles suitable for mounting 19” width 2U height equipment (power supply and terminal blocks) shall be provided.
Complete frame structure shall be of made of steel structures. The cabinet shall be made from Cold Rolled Steel (CRS) Metal (14 Gauge) with powder coated finish.
The structure shall allow easy assembly of Gland Plate, Monitor arms etc in extremely rigid manner.
Rear access doors shall provide accessibility for easy installation, operation& servicing of the equipments inside the console.
The console shall be designed to have adequate space for accommodating the equipments.
The Console shall have earthing provision in structure. Console cabinet shall be provided with fan for Cooling. The console shall be provisioned with concealed electrical
outlets, information outlets (LAN) and RJ-11 Telephone jacks. The provision for mounting of electrical outlets and telephone
jacks shall be designed for flexible placement of monitors, telephones, intercommunication units and laptops on the console with zero cable clutter on the work surface.
Industrial grade metal powder coated finish Universal socket type Power Distribution unit (5A, 5Nos and a master MCB) must be provided for power supply.
Cable entry holes shall be provided in Support legs of the cabinet for data and power cables entry in console cabinets.
PVC cable ducts with covers shall be provided for concealed and neat cable routing.
Grommets/Gasket shall be provided for cable entry holes to avoid damage of cables.
Sharp edges at the consoles base shall be avoided. End Panels:
The end panels shall be with glossy finish and should seamlessly integrate with the structure.
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The leg cover element shall cover the structure and should increase the aesthetic look of the console.
The end panels at the extreme end of consoles shall matching curved shapes designs.
Detailed Engineering phase
The party shall submit samples of solid acrylic material and different variants of colors available.
Vendor/Manufacturer shall ensure that the design is ergonomically sound and has excellent aesthetics.
Based on the designs and samples submitted by the supplier, the department will evaluate and decide the color and dimensions.
During this evaluation, Department may suggest minor modifications and the vendor shall be willing to accommodate such modifications.
After the finalization of design, the party shall submit fabrication drawings.
Pre-fabrication review to include submission of drawings and complete components listing of selected finish materials.
Fabrication & Sample Inspection at factory site
After the approval of the fabrication drawings by the Department, the party shall fabricate one sample console segment and one data processing table.
After the approval of sample by Department, final fabrication shall be carried out.
The offered product shall be manufactured using high quality components and shall processes to ensure consoles of high quality, good surface finish, durability and reliability.
Final Acceptance & Commissioning at site
Photographs of assembled consoles and data processing table shall be furnished prior to dispatch and proper international standard air worthy packing to be used to ensure undamaged and complete arrival at the destination.
Vendor shall take installation and commissioning of the console at Department site.
The vendor/manufacturer shall be a fully responsible for the commissioning of product including all design services, metal work, woodwork and millwork to ensure product consistency and lead-time.
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Fully detailed assembly instructions in the English language shall be supplied with both written and pictorial descriptions for each item/model numbered component with dimensions.
1.C.21 SPECIFICATION OF POWER CABLE
Type : PVC Insulated and PVC sheathed, flexible three core
multi stranded copper cable Voltage grade : 1.1kV Size of conductor : 2.5 mm2 Current rating : 16A No of cores : Three (Red, Black and Green) Conforming standard : IS/IEC standards
1.C.22 SPECIFICATION OF EARTHING CABLES
Inner conductor : Multi Stranded copper wire of size 12 AWG
Insulation : PVC
Colour : Green
1.C.23 SPECIFICATION OF TERMINAL BLOCKS
Type : Cage Clamp
Insulating material : Polyamide 6.6
Contact material : Tinned Copper
Size of the wire : 12-22 AWG
Colour : Grey
Cable entry : Front, Top
Current rating : 10A
Nominal Voltage : 600V
Rated Surge voltage : 8kV
Pollution Degree : 3
Voltage category : III
Flammability : UL94 V0
Compliance standard : IEC 60947-7-1
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Mounting : Din rail: 35mm width
Accessories : End plate, Mounting rail,
Marking ferrule.
Types I
No: of terminals : 2
No of levels :1
Types II
No: of terminals : 4
No of levels :2 with internal short link.
Types III :
No: of terminals : 4
No of levels :2 with cross link 3 pole.
Types IV
No: of terminals : 2
No of levels : 1
Colour : Separate for Phase, neutral and earth.
: Phase: Red ; Neutral : Black; Earth : Green
Size of the wire : 2.5 sqmm
Cross link : 3 Pole and 5 pole
All Accessories like Separators, marking labels and end stoppers shall be included
as one lot
Note:
The party shall provide detailed catalogue along with offer indicating the part
number of items and specifications.
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1.C.24 INDICATORS, SWITCHES AND KEYS
i. INDICATORS
1. Connection Method : Plug-in
2. Type of Head : Square
3. Illumination colours : Red, Green, Yellow
4. Illumination type : LED
5. Contact type : Silver
6. Service category : 24VDC ; 1A
7. Approximate dimension : 24mmx18mm
8. Mounting depth : 45mm
ii) SWITCHES WITH INDICATORS
1. Contacts : NO-3; NC-3
2. Switching Action : Maintained Action at two positions
3. Ingress Protection(IP) : IP40
4. Connection Method : Plug in
5. Type of Head : Square
6. Illumination colours : Red, Green, Yellow
7. Illumination type : LED
8. Contact type : Silver
9. Service Life : >2x106 cycles
11. Service category : 24VDC ; 1A
12. Approximate dimension : 24mmx18mm
13. Approximate Mounting
depth
: 45mm
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iii) KEYS
1. Contacts : NO-3; NC-3
2. Switching Action : Maintained Action at two positions
3. Ingress Protection(IP) : IP40
4. Connection Method : Plug in
5. Type of Head : Square
6. Key removable position : Position1 alone
7. Contact type : Silver
8. Service Life : >5x104 cycles
9. Service category : 24VDC ; 1A
10. Approximate Mounting
depth
: 50mm
General:
Ambient temperature : 15deg C to +60 deg C
Rated Insulation Voltage : 300V AC
Over voltage category : III
Degree of Pollution :3
Electrical specification compliance : IEC 512-2-11
Shock Resistance : IEC 512-4
Accessories:
Protective covers, Blind plugs, labels, spare keys shall be quoted.
Note:The party shall provide detailed catalogue along with offer.
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1.C.25 MCB
1.
2.
3.
4.
5.
6.
7.
8.
No. of poles
Type /Series
Rated current
Rated Voltage
Rated Frequency
Breaking capacity
Rated insulation voltage
Rated impulse voltage
:
:
:
:
:
:
:
:
Single pole
D curve
0.5-63A
240/415
50 Hz
10kA
690V
4kV
9. Minimum operating voltage
: 230V AC, 50Hz
10.
11.
Fixing Installation position
: :
On symmetric rail EN/IEC 60715 or DIN 35 Vertical/ Horizontal
12. Ambient working temperature
: -5 to +55 0C
1.C.26 PLC based control system including instrumentation works
1.C.26.1 CONTROL SYSTEM - GENERAL REQUIREMENT
1. The system architecture shall provide the necessary hardware and
software to satisfy the following major functions
i. Process Interface: Interface to the process shall be through AI, DI,
AO, DO modules.
ii. Controller shall be capable of performing control of the process via
I/O modules
iii. Programming Node: This shall be a high performance workstation
type computer capable of Programming and configuring any
Control system device.
iv. Communication Network: A high speed network connecting all the
modules of the Control system.
v. Operator station: Operator stations shall be LED type screen
capable of displaying Control system information, process
information and other sub-systems connected to the same.
I/O channels for each parameter is given in table
The detailed input/output requirement is shown in Table 2.2.
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Type Main (Qty)
Digital input (DI) for E/P valve, pump control and console switches including spare
32
Digital Output (DO) ) for E/P valve, pump control and console switches including spare
24
Analog Input (AI) (0-10V) for pressure, Level, flow and pump control including spare
32
Analog Output (AO) (4-20mA) for pump control including spare
8
Programming, SCADA and Data storage node 3 + 1 (Spare)
Printer 2 nos. (B&W-1 no. and Colour-1 no.)
Pump control valve I/O channel requirements to be finalized after detailed
engineering.
1.C.26.2 System Facilities
1. The Control System shall scan all the Digital and analog data from field
elements in every cycle time and logical operation to be performed.
2. The system shall be hot swappable and vendor shall demonstrate the
feature for the system.
3. System shall have high ruggedness in respect of isolation between
electronic modules.
4. System shall have the provision to interface IST code reader and display
the same.
5. The system should be highly resistant to Electro-Magnetic interference.
6. System should have smart features of internal diagnostics.
7. In case of failure of any module in the control system replacement of the
module shall be possible, and it shall not lead to change in software or
requirement of additional software.
8. All I/O nodes shall have network redundancy.
9. The controller shall transmit the data to Programming, SCADA and
storage nodes through Ethernet for online display, storage and offline
data analysis. It shares the same to mimic, processing station, Printers etc.
for control, real time display and acquisition through Ethernet LAN.
10. Programming, SCADA and data storage node shall be loaded with latest
versions of Windows or LINUX Operating Systems with necessary
Drivers and Software for Centralized Acquisition, monitoring and data
reporting.
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11. Program development and animation of mimic diagrams required for the
project is under the scope of vendor.
12. Necessary storage devices shall be provided for data acquisition, storage
and retrieval for the system to meet the 10samples/ second data
acquisition rate.
Codes & Standards
13. IEEE 12207 System and software engineering-Software life cycle process
14. IEC 61131-3 International standard for PLC programming languages
15. Preferred Control system Make: Siemens/ GE/ Allen
Bradley/Honeywell/Schneider/B&R/Sigmatek/ABB/Mitsubishi
1.C.26.3 DETAILED SPECIFICATIONS
1.C.26.3.1 CONTROLLLER/PROCESSOR
1. CPU shall be high performance latest version with necessary parallel
processors having standard control unit and arithmetic logic unit (certified
for Industrial Control applications).
2. The CPU shall confirm to the following
i. In built floating point processor.
ii. Crystal controlled real time clock with battery backup better than 10
ms resolution (option) & it should be stable for 72 hours with an
accuracy of ≤ ±1s. The stability for one hour shall be ≤ ±5ms
iii. Watch dog timer protection
iv. Isolated power supplies
v. Communication interface : 100/1000 Mbps data rate with built in or
separate communication module to communicate with high speed
switches from PLC to I/O node, and operator stations through
TCP/IP, Modbus or other proprietary protocols.
vi. Capability to handle priority interrupts
1.C.26.3.2 MEMORY
The CPU memory shall be on board and shall conform to the following
i. The CPU shall contain the program memory at RAM level, and
Application program in EEPROM/Flash EPROM.
ii. CMOS shared RAM memory with battery backup. The capability
shall be such that it should be sufficient enough for configuration of
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all data base and control strategies for the current I/O quantities
plus the 20% of growth and also extra memory of 20% for future
expansion requirement. Requirement of spare memory capacity can
be decided / finalized on approval of Purchaser.
iii. Greater than 64 MB DRAM and greater than 512 KB user SRAM
iv. Flash Memory shall be greater than 64 MB
v. Power back up shall be provided for memory storage programs.
vi. Shutdown resetting shall be possible manually and confirmation of
the same after that all variables and concerned has returned within
normal conditions.
vii. Even though the hardware details of the control module is specified
here, Vendor can recommend/offer a better & latest CPU and other
hardware to meet this system requirement. The suitability will be
reviewed by Purchaser.
viii. Vendor to certify system response time, type of memories, backup,
percentage of loading etc.
ix. System scan time ≤ 500 ms (including 64 K application program, 8
PID loops )
x. Detailed calculation demonstrating scan time to be provided along
with offer.
1.C.26.3.3 INPUT/OUTPUT MODULES
1. The following types of I/O modules are required
Analog Input (AI) [0-10V DC]
Digital Input (DI)
Analog Output (AO) [4 -20mA]
Digital Output (DO)
2. These modules are to be interfaced with Department supplied devices
like isolated barriers/relays.
3. All I/O modules shall be rack mounted in an enclosure which is
proximal or integral with the associated control module.
4. All I/O modules shall be slot independent.
5. All I/O modules shall be hot swappable. The back plane shall permit the
removal of I/O cards without the need to isolate power supply to the
card.
6. Time synchronization between all I/O bases is required.
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7. All the I/O terminations from the I/O module shall be wired to
connectors in the system cabinet.
8. Each I/O module shall contain status display LEDs on the front panel of
the module itself.
9. Digital I/O module shall contain status display LEDs for individual
channels at the front panel of the module.
10. Forcing/ simulating of analog and digital outputs shall also be a
standard feature. Indication and logging of the simulated signals shall be
made available. Disabling/ normalizing the forcing on individual
channel basis as well as card basis shall be possible.
11. Environmental conditions:
Operating Temperature: 0-50 Deg C,
Humidity: 0-95 %, non condensing
A. Analog Input Module
a) No. of channels :8 per module
b) Input type : 0 to 10 V DC
c) Resolution : ≥ 16 bit
d) Input Impedance :> 1 M ohm
e) Overall Accuracy : ≤± 0.2%
f) Conversion time for all channels in a module < 50ms
g) Electrical Isolation : Input to PLC > 250 V rms
B. Analog Output Module
a) No. outputs :8 per module
b) Output Signal :4-20 mA
c) Resolution : ≥ 16 bits
d) Conversion time : <50 ms
e) Overall Accuracy : ≤± 0.2 %
f) Load Resistance : <500Ω
g) Electrical Isolation : >250 V rms (Output to PLC bus)
h) Short circuit protection to be provided.
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C. Digital Input Module
a) No. of inputs : 16 per module
b) Input voltage(Nominal) : 24 V DC
c) Input voltage(Maximum) : 28 V DC
d) Switching Threshold
i. Low : < 5V
ii. High : > 10V
e) Input Resistance : > 2KΩ
f) Switching Delay : ≤5ms
g) Input Current : < 10 mA
@ maximum input voltage
h) Electrical Isolation : : > 250 V rms (Input to PLC)
D. Digital Output Module
a) No. of Outputs : 16 per module
b) Type : Transistor
c) Output Voltage : 24 V DC (nominal)
d) Minimum voltage : 20V DC
e) Maximum voltage : 28V DC
f) Continuous Current : ≥ 0.1 A per Output
g) Electrical Isolation : > 250 V rms Output to PLC
h) Short circuit protection to be provided
i) Overload Protection to be provided
j) In case of failure of processor, the digital outputs shall remain in fail
safe (OFF/de energized) state.
E. COMMUNICATION REQUIREMENT
1. The controller shall transmit the data to Programming, SCADA and
Data storage node through Ethernet for online display, storage and
offline data analysis. It shares the same to mimic, processing station,
Printers etc. for control, real time display and acquisition through
Ethernet LAN.
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i. The industrial grade Ethernet bus shall operate at 100/1000
Mbps.
ii. Work stations are to be connected via Ethernet links and
Ethernet switch and shall communicate on TCP level.
2. The Controllers shall have suitable communication interfaces to
establish communication between Programming, SCADA and Data
storage node, I/O nodes and programming node.
3. Operator station/SCADA level network and PLC network shall be
independent.
1.C.26.4 INDUSTRIAL MANAGED ETHERNET SWITCH
SL.No Parameter Specification
1 Type Layer 2 Industrial manageable switch
2 No. of ports >8X10/100 BASE-TX Ports
2XCombo 1000BASE-T/SFP 100/1000
ports
4 Switching
capacity
10Gbps
5 Transmission
Method
store and forward
6 L2 Features SNMP/RMON/BOOTP/Telnet/Web
Network management protocols Port
trunking
802.3 Ethernet,802.3u Fast Ethernet
802.1d Spanning tree,802.1 W Rapid spanning tree,802.1P Priority tags, 802.1q VLANS,802.1ac VLAN Tagging,802.1 ad Link Aggregation control,802.3x Flow controls,802.1x MAC Based Network Access Control,IPV6 support Redundant 24V DC power input and relay output for fault indications
7 Security IEEE 802.1x Port -based/MAC based control, Port security, DHCP snooping, SSH, Dynamic Arp Inspection, Access Control List, RADIUS,TACACS+ Broadcast/Multicast/Unicast Storm Control
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8 Management Telnet,
CLI/ConsoleHTTP,SNMPv1,v2/v3,SSH
9 Quality of
Service
Ingress policing, Rate-Limit, Egress Queuing/shaping, Auto Qos
10 VLANS 255 static VLANS
11 Enclosure IP30 Aluminium Metal Case
12 Installation DIN Rail
13 Power supply 230VAC/24VDC
14 Current
consumption
< 420 mA at 24VDC
14 LED Indicator Link/Activity for RJ45 and Fibre ports
15 Operating Temp.
15 to 65 deg C
16 Relative
Humidity
10 to 95% Non- condensing
17 EMC CE,FCC Class A
18 Warranty 3 Years.
1.C.26.5 ETHERNET CABLES
a) Category : CAT5e/CAT6
b) Type : Stranded and Twisted pair
c) Wire Gauge : 24 AWG
d) Length : 500m continuous
e) Wiring standard : T568B
f) Cable impedance : 100 Ω
g) Operating temperature : -10C to 60C
h) Connector : Molded connector shield as per EIA/TIA 568B with
gold contacts more than 50 and twist protection, with plastic injected
protection, 2 x RJ45.
i) Boot: Molded Gray Boot with pressing clip around each connector,
shielded with RJ45 connector, with integrated molded pressing clip for
pressing the RJ45 connector clip.
j) Recommended Brands: D-Link/ AMP / Beldon
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1.C.26.6 PROGRAMMING STATION, OPERATOR STATION & DATA PROCESSING STATION
1. Programming station shall be capable of project development and be
capable to upload and down load the user program to controller.
2. Data processing station shall be loaded with all required software for
data acquisition, logging and reporting.
3. Operator station shall be capable of continuous display for 100 hours.
4. Specification
CPU : All in One PC
Processor : Intel Core i7 or latest at 3.6 GHz
Memory : 2 x 4 GB DDR3 /DDR4 upgradable to 16 GB
( 4 DIMM slots)
Hard Disk : 1TB SATA III with 10,000 RPM
DVD Combo
: DVD Super Multi Drive
Video : Integrated Graphics Media Accelerator x4500 support upto 256 MB video memory through DVM, support direct X10
Audio : Intel High Definition Audio
Ethernet : 1. Mother board -1 No.
2. Additional Network Interface Card- 1 No.
Monitor : 23.8” TFT LED Wide Monitor resolution of 1440x900 & built-in speaker
Keyboard : Multimedia keyboard with USB 2.0 Interface
Mouse : 2-Button optical scroll mouse with USB 2.0 Interface with Mouse Pad
Operating System
: Preloaded with Genuine Microsoft Windows 7/10 Professional or latest OS with license & recovery media/Linux suitable for PLC.
Software : Required drive software for Mother Board/Chipset Driver in CD, NIC & DVD writer
Input power
: 230V AC @ 50Hz with Indian Standard Plug
Preferred makes: Dell/HP/Acer
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1.C.26.7 PLC SOFTWARE AND PROGRAMMING
1. The supply shall include all software required for developing the
application programs, graphics, event sequencing, alarm history, PID
loop, their modification and debugging.
2. Software shall be menu driven and easy to use. It shall incorporate on-
line tutorials and help functions to assist the user.
3. The programming language shall be powerful, intelligent and user
friendly for every stage of work and up to operation for planning,
designing interlock logics, online / offline testing, maintenance.
4. Software shall be self-documenting and shall provide cross-reference
tables, I/O configuration tables and associated functions.
5. System software for writing application shall run on latest version OS.
6. PLC shall have the provision for on line and off line programming with
Hardware/Software lock.
7. Programming station shall be capable of project development and be
capable to upload and down load the user program to controller.
8. Development licensed Software shall be provided to the programming
node.
9. The software shall be easily loaded from CD/DVD media and shall be
easily configurable in case of software crash/system failure.
10. All hardware & software shall be the most recent, field proven
models/versions and revision levels marketed by their manufacturers at
the time of proposal submission.
11. The following programming languages and tools but not limited shall be
provided.
i. Programming (IEC 61131-3 Compliant): Ladder Diagram (LD),
Functional Block Diagram (FBD), Structured Text (ST), Instruction
List (IL), and Sequential Functional Chart (SFC) and C language
(optional).
ii. Graphics editing software with all necessary tools
iii. Drag & Drop facility for graphics and programming
iv. Zooming, resizing, rotating, grouping & layering facility in graphics
v. Faults status (accessible via the applications software)
vi. On-line data modification.
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vii. Exporting/importing standard objects/images
viii. Input / output forcing or simulating
ix. Fault status display in different group shall be provided
x. Tools for alarm management
xi. Online documentation for operation & programming
12. The programs and logic diagrams implemented in the system shall be
available in printed form by means of the printer.
13. Suitable Network Diagnostics software shall be provided to monitor the
Network Traffic.
14. Validation tools to identify version changes in software codes.
15. Supply of source code for above mentioned operations with details for
modification during future requirement (For application program)
16. Development licensed Software shall be provided to the programming
node.
17. Run level licensed Software shall be provided to all the workstations.
1.C.26.8 OPERATOR STATION SOFTWARE REQUIREMENTS
1. The SCADA runtime software shall be planned in operator station.
2. PLC data shall be made available in SCADA node for monitoring in
operator station mimics. Command generated from operator station
mimics shall be communicated to PLC for command execution.
3. The development package should provide necessary tools to test the
individual tasks that are generated at the SCADA package.
4. The development package should provide facility to maintain version
management of the total software being developed.
5. Provision shall be provided in the software such that same function can
be used by multiple objects.
6. Graphical tools to develop required mimic pages. Software shall have
provision to import images, grouping, dragging, resizing, editing of
objects.
7. All the objects created for animation of EP valves, control valves, analog
parameters can be accessed by TAG names.
8. Maximum of 2K tags are required in SCADA.
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9. Online debugging of SCADA packages under development should be
possible. This should cause minimal disturbance to the runtime system.
10. The development package should consist of a full-fledged online help
system in English with provision for context sensitive help.
11. The graphic building utility with full-animated graphics should provide
necessary support to import custom photographs as background images.
The package should support user configuration for animation of the
graphics objects in runtime Environment.
12. Graphical utility to develop mimic pages and PID control panels.
13. System should provide real time Trend display and Bar chart with alarm
conditions of critical parameters to be displayed by visual indication (eg.
color change) and audio signal.
14. Provision to select different mimic pages with function key.
15. Screen update time should be less than 1 second
16. The development package should be executable simultaneously along
with the run time system. The development package should allow
updating the existing run time system with a newly developed run time
system with minimal disturbance to the runtime system.
17. Provision should exist for developing user triggered pop-up messages
and alerts with customizable command on the popup messages. These
popup messages and closing the messages by either operator action event
or program triggered variables should exist.
18. User defined alarms and events should be configurable for their
properties and messages. All alarms and event should be immediately
logged in a database time tagged with the IST. The alarm/event Database
access for online/offline viewing and extracting data should be provided.
Necessary tools for customization of the event/alarm reports should be
provided.
1.C.26.9 Sample SCADA screen format id given in SCADA BASED PID LOOP
1. PLC /SCADA based PID loops are used to operate the pump control for
controlling flow.
2. Parameters to be controlled are given as feedback signal to PLC based
control system. Pump has to be operated either in manual or auto mode
through SCADA.
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3. Proportional (P), Integral (I) and Derivatives (D) constants are
programmed through SCADA.
4. In manual mode, the speed of the pump is varied through SCADA.
5. In Auto mode, the speed of the pump is controlled by comparing the
feedback signal with set point value and output (4-20mA) to be generated
based on Proportional (P), Integral (I) and Derivative (D) constants set.
The set point value can be varied through SCADA from operator station.
6. The PID loops shall have auto tuning feature and provision to enter
manually the PID constants.
7. Program to be developed to accept the speed of pump through
keyboard/virtual keypad with confirmation.
8. The PID loop software shall have the provision to control the speed of
pump by external step input, ramp input or trigger inputs.
9. PID loop standard libraries shall be available for control purpose such as
ratio control etc.
1.C.26.10 DATA ACQUISITION, LOGGING & REPORTING SOFTWARE
1. Data acquisition, logging and reporting software shall have capability to
Acquire, store and report all required Digital and Analog Parameters wired
to control system in graphical and numerical format at required time
intervals. The minimum time interval in 500ms.
The time stamping of data with IST code reader shall be possible.
Store all events, process parameters and alarms with their description,
occurrence time and priorities and print out of the same on demand.
Provide report in portable document format or Microsoft Excel format.
Provision to start /stop the acquisition system without affecting the
functioning of the control system and monitoring of the acquired data in
operator station.
2. Database with channel Tag names, description, Sensor constants for
engineering unit conversion, sensor range shall be prepared and loaded in
programming node.
3. This database shall be used to retrieve the data in engineering unit.
4. This software shall be loaded in data processing node and run versions shall
be made available in operator stations so that online/offline viewing and data
extraction shall be possible.
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5. The software shall allow the operator to edit, replace values or insert new
values in database records. Altered values in the database shall be tagged for
reference purpose.
6. The software shall be capable of providing online display in numerical and
graphical format.
7. In on line graphical display, countdown time referenced to external
synchronization signal or universal time shall be followed. Maximum of four
different Y scales shall be possible. The parameter range for each Y scale shall
be programmable. The parameters to be plotted shall be selectable from the
I/O list. The same feature shall be made in offline graph also.
8. System shall have provision to acquire & retrieve the analog/ digital
parameters at different sampling rates (500ms, 1s, 5s).
9. Data reporting software for processing of all analog and digital I/O’s shall be
developed and loaded with reference to IST code reader for printing and
plotting in offline.
10. The software shall be capable to retrieve, print and plot the data in
engineering unit and raw data formats.
11. Provision to process and print out / plot the analog and digital data through
network from all operator stations.
12. Perform input signal smoothing, averaging etc. as required.
13. Alarm limit checking for various types of alarms such as deviation alarm,
absolute alarm etc.
14. System shall store all data including process variable, set points and
manipulated outputs at different sampling rates.
15. 1 hour acquired data shall be retrieved within 5 minutes.
16. Data reporting software shall process and store data for the maximum
duration of 24 hour data with 500 ms interval.
17. For every restart or when the file size exceeds 700 MB, new data file shall be
created automatically with unique configuration file name without any data
loss.
18. The data reporting software for plotting analog & digital parameters
separately and with the option to mix up both parameters shall be developed
and loaded.
19. The backup of raw data shall be made in CD /DVD.
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20. The raw data shall be split into multiple files of 700MB size for CD backup.
21. The data reporting software for analog parameter should take 4th order
curve fitting sensor constants for engineering unit calculation in on line
display, offline print out and trend.
22. Source code for software with details for modification during future
requirement shall be provided.
23. Processed data suitable for online test server should be confirmed and
modified accordingly.
1.C.26.11 APPLICATION SOFTWARE
1. Application program shall be written in a logical fashion to simplify
maintenance and trouble shooting. Logic for a specified requirement shall
be grouped together. Identical equipment controlled in a similar manner
shall have similar logic structures except for tag numbers. I/O modules
shall be grouped in a logical fashion. I/O module allocation shall be done
in such a way that failure of a single module affects only the particular
module.
2. The supplier shall develop and demonstrate sample of all required
software as per details given below during FAT and SAT. The software
design document, source code, validation and verification procedures
shall be given by the vendor.
3. Auto Sequence
i. The auto sequence is used for operating field control elements in
auto mode. The time and parameters based sequence shall be
developed in Control system using PLC programming language.
The programming shall have the flexibility to change the variables
(time, Analog & Digital) through separate Input data files. The time
base event should be synchronized with software timer.
ii. Separate Data Base files to be incorporated for Analog & Digital
constants/details for Processing & Display.
4. Interlock and Auto Abort
i. The interlock and abort logics shall be developed using PLC
software. Various parameters to be compared as per the logics (1/2
or 2/2, or 2/3 or 2/4) provided for the set limit and a set of time
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based abort sequence to be executed. The program shall have the
flexibility to change the variables (time, Analog & Digital) through
separate data table to execute abort sequence. The logging of
Interlocks enable/ Disable, setting and generation of Alarm limit,
execution of interlock shall be provided for offline analysis.
ii. The program shall have the flexibility to enable/disable a particular
interlock/abort group.
iii. Generating alarm contacts, for audio visual alarm, event logging etc.
iv. Interlock for controlling field equipments such as E/P valves, Pump
control etc.
v. The system shall also execute Safety interlocks to provide safe test operation under abnormal conditions. For Automatic operation of various elements during preparation phase and during test, the required sequence of operations is to be programmed based on predetermined timings and/or limits of process parameters for parameter based operations.
vi. The Operator Station shall have facility for monitoring and operating each interlock group through soft keys / key board / mouse. There shall be facility for accessing interlock logic groups in one key stroke which shall be freely configurable.
vii. During operation, the system has to monitor critical facility
parameters and abort the sequence if the majority of parameters in
any abort group exceed the limit.
viii. The alarm indication is to be available as alarm summary/ pop up
window/ logging in file/ display.
ix. Program shall have the flexibility to change the logics, parameters,
limits, validity time through separate data table/ input files.
1.C.26.12 SITE ACCEPTANCE TEST (SAT)
All the equipment shall be thoroughly checked after receipt on site. The tests
shall include but not limited to the following in the presence of Vendor’s
commissioning Engineer.
Vendor shall do powering of panel at site after verifying termination at
cabinets. Site acceptance test shall be started only after the satisfactory
performance of loop checking and verification of records by Purchaser.
The site acceptance test shall be carried out in the presence of Purchaser’s
authorized representative at IPRC, Mahendragiri.
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The Department supplied SCADA support will be provided for the required
tests during SAT. All the performance specification of the control system
with the field terminations will be verified and supplier should demonstrate
the following major performance as a minimum:
1) Hardware verification as per final bill of material
2) Visual and mechanical check-up for proper workmanship, identification, ferruling, nameplates, etc.
3) System configuration as per approved configuration diagram
4) Demonstration of all system diagnostics
5) Cycle time verification 500ms along with 64K application program with full load (with all mimic diagrams in all nodes). The checking conditions stated in FAT shall be followed here also.
6) Demonstration of failure cases and verification of error indication in diagnostic mimic
7) Recording of time based events
8) Demonstration of security login levels
9) 500 ms for all analog data acquisition
10) 500 ms for all digital data acquisition
11) Isolation & accuracy check of all I/O cards.
12) Functional verification of all I/Os
13) Real time display & data reporting software for continuous acquisition of 24 hour.
14) Demonstrating the network speed with full load
15) Error diagnostics of the network failure, system failure, I/O failure.
16) Fail safe mode condition to be demonstrated in case of any failure of CPU, power supply, interface cards, communication, I/O cards etc.
17) Ensuring system behavior over a duration of 10 days with multiple restarts.
18) Auto and abort sequence, interlock application program
19) Event & Analog data retrieval in the required format within five minutes for acquired continuously for 1 hour.
20) Retrieval of Digital & Analog data as per the requirement
21) Plotting of Analog Data
22) Archiving of Data
23) Demonstration of PID loops
24) Checking of proper functioning of all disc drives, alarm summary,
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printers etc.
25) Burn in test for 72 hours & any other mutually agreed test.
26) Time accuracy check
Any malfunctioning in the system shall be rectified /replaced as required. Failure of any component shall be replaced with new one. No repaired
parts/modules shall be accepted.
After confirming that the control system is meeting all requirements, the
total system will be switched on continuously for 3 days and performance of
the system will be monitored. On successful completion of the above period,
if the performance of the system is satisfactory, Department and supplier
will provide the acceptance test certificate jointly.
Client shall take over the system from the vendor after the final acceptance
test, which is defined as successful operation of the integrated system. The
vendor’s personnel shall be present up to this period.
The Purchaser shall provisionally takeover the systems from Vendor after
Site Acceptance Test.
After SAT, one service engineer to be provided for local support to maintain
the system. The person shall have a sound technical knowledge in both H/W
& S/W of the supplied system and capable to ensure a trouble free
operation.
Note: This specification provides the minimum requirement of the system but it does not relieve the supplier from his responsibilities for completeness of the system concerning the design, the reliability and the safe operation of the supplied equipment. Site preparation, Erection and Commissioning of the complete system work shall be quoted in lump sum amount and not in man hour basis
Moreover, it is stressed that Control System (Hardware & software) shall be of latest proven model manufactured preferably and shall be supplied on turnkey basis.
1.C.27 GUIDED WAVE RADAR LEVEL SENSOR 1. Type : Guided wave radar
2. Measurement Principle : Time Domain reflectometry (TDR) 3. Medium : IPA 4. Measuring range : 3m(The exact length will be
provided at the time of
detailed engineering.)
5. Process pressure : 10 bar 6. Process Temperature : 300K 7. Accuracy : 3mm or 0.03 % of measured
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distance whichever is
greater
8. Repeatability : better than 1mm 9. Ambient temperature effect : 0.2 mm/K 10. Update interval : < 1 sec 11. Reference condition : 298 K and ambient pressure
in IPA
12. Microwave output power : 0.3mW to 45 mW 13. Display : Integral digital display to
be provided to display the level
14. Output : 2 wire, 4 to 20 mA analog output and HART signal superimposed on analog output
15. Power supply : 16-42 VDC
16. Probe type : Coaxial/Flexible with centring disc 17. Material : SS316L 18. Process connection : 2” Flange, ANSI 150# CL 19. Housing material : Polyurethene covered
aluminium
20. Ingress protection : NEMA 4X and IP 66 21. Hazardous Location : Intrinsically safe certified
ATEX II 2G Ex ia IIC T6.
22. Vibration resistance : Housing : IEC 60770-1 Level1
23. Electromagnetic compatibility : Emission and immunity
:EN61326-1:1997
2. FABRICATION, ERECTION AND COMMISSIONING
The system shall be fabricated, erected and commissioned as per
the following procedure:
2.1. Fabrication
All the fluids circuits shall, as far as possible, be fabricated in the
Contractor’s factory in such segments that they can be transported
by road. All the circuits shall be fabricated primarily by welding.
The other joints such as flanges, threaded unions, etc may be
resorted to in such cases where removal of the joints becomes
inevitable like pressure gauges/ transmitters, safety relief valves,
etc.
2.1.1. Pipe bending
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The pipe bends may be employed in lieu of elbow fittings wherever
possible. The bending process shall produce wrinkle-free bends.
Unless specified otherwise, the radius of curvature measured to the
centre-line of the pipes shall be equal to 3 times the nominal pipe
size (diameter). The bending shall normally be done in cold
condition. However, hot bending may be resorted to in certain
cases with the approval from the Department.
2.1.2. Welding
All the welding of SS pipe-lines shall be performed by Gas-purged
Tungsten Arc Welding (GTAW) with Gaseous Argon (99.995 %
purity) as the purge medium. The welding processes shall comply
with the requirements of Section IX, ASME.
The welding procedure qualification and welders’ performance
qualification shall be done as per Section IX, ASME.
2.1.3. Tests
The following tests shall be performed after fabrication of pipe-
lines:
a. Dye penetrant test: All the butt and mitre welded joints shall be
subjected to DPT at the root pass.
b. Radio-graphic test: All the (full) SS butt welded joints shall be
subject to radio-graphic test to 2% equivalent sensitivity.
Generally, the radio-graphic tests shall be done with X-rays.
Alternatively, the gamma rays may be used in locations where
the joint is inaccessible to X-ray equipments. All the radio-
graphic films shall be submitted to the Department.
c. Pressure test: All the fabricated pipe-lines shall be subject to
pressure test with hydraulic medium at 1.5 times the MAWP.
Alternatively, in pipe-lines, where the presence of water is
intolerable, the pressure test may be done with pneumatic
medium at 1.1 times the MAWP.
d. Pneumatic leak test: All the pipe-lines, except those for water
medium, after attaching all components shall be subject to leak
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test with GN2 or dry Air at 0.85 times the MAWP to validate
bubble-tightness.
e. Surface oil contamination test: The surface oil content of the
pipe-lines shall be measured by transferring the oil contaminant
into a solvent by mopping the surface and analyzing with
Spectro Fluoro photometer. The permissible surface oil
contamination shall be 200 mg/m2.
2.1.4. Cleaning
The fabricated SS pipe-lines shall be cleaned as per the following
procedure:
a. Mechanical cleaning: All the metallic surfaces with scales and
newly welded surfaces shall be cleaned by scrubbing with SS
wire brush. The loose particles generated by mechanical
cleaning shall be removed by blowing with compressed air,
sucking or washing with water.
b. De-greasing: The oil and grease adherent to the surface shall be
removed by vapour phase de-greasing with Tri Chloro Ethylene
(TCE) or Per Chloro Ethylene (PCE), followed by liquid phase
de-greasing with TCE or PCE.
c. Pickling: In order to remove rusts and scales, the surfaces shall
be washed with water and pickled with a solution containing
Hydro-fluoric acid (HF) and Nitric acid (HNO3). The
composition of the pickling solution and duration are to be
adjusted after trial test on a sample piece to remove uniformly
less than 25 m thick material. Mostly, the composition is as
follows:
HF : 5 % by mass HNO3 : 15 to 20 % Water : Remainder
This is followed by rinsing with water.
d. Passivation: The surfaces shall be passivated with a solution of
the following composition:
HNO3 : 25 % by volume Water : Remainder
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Duration : 2 hours This is followed by rinsing with De-mineralised water.
e. Preservation: The volume inside the pipe-lines shall be dried by
compression-decompression cycles [or any suitable alternative
method(s)] with GN2 or dry Air to reduce the moisture content
to ≤ 20 ppm. The ends of the pipe-lines shall be blanked off
during transportation and storage. The pipe-lines shall be kept
pressurised with GN2 or dry Air at 1.3 to 1.5 bar during
transportation and storage.
2.1.5. Painting
All the SS pipe-lines shall be painted with the identification bands
of 100 mm width at 2 m span based on the colour code scheme. All
the pipe-lines, flow components and instruments shall be provided
with identification name plate displaying, in bold letters, their tag
numbers. All the structural materials shall be painted in grey colour
and hand rails in yellow colour. The colour code scheme shall be
provided upon award of the contract. Prior to painting, the surfaces
shall be suitably prepared. The painting shall comprise 2 coats of
primer (like red-oxide) and 2 coats of synthetic enamel.
2.2. Erection
During erection at the Department’s site, the equipments supplied
by the Contractor shall be mounted and the fabricated pipe-line
segments received from the Contractor’s factory joined by the
Contractor. All the machineries required for erection such as
welding equipments, grinding machine, drilling machines, radio-
graphic equipments, etc, consumables such as Gaseous Argon and
Helium, hacksaw blades, etc and tools & tackles, etch shall be
arranged by the Contractor. The works to be done by the Contractor
during erection shall be as follows:
2.2.1. Minor civil works
The minor civil works shall be done with Plain Cement Concrete
(PCC), Reinforced Cement Concrete (RCC) and brick masonry, as
required. The minor civil works are required for
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a. Grouting of equipments, pipe supports, structural works, etc
b. Breaking and making holes across walls for laying pipe-lines
c. Excavation and levelling of ground wherever required for laying
the pipe-lines and providing pipe supports. In some locations, it
may be required to break and excavate already laid PCC/ RCC
pavements for grouting
d. 2 coats of white washing of the concrete surfaces after
plastering.
All the materials such as torr-steel reinforcement rods, binding
wires, brick, cement, sand, gravel, etc shall be arranged by the
Contractor. The composition of concrete shall be as follows:
a. PCC – Cement : Sand : Gravel = 1:5:10
b. RCC – Cement : Sand : Gravel = 1:2:5
2.2.2. Mounting of equipments
The mounting of equipments under the scope of contractor shall comprise the following:
a. Loading of the equipments on the trailer/ lorry by using crane, fork lift or any other safe and suitable material handling equipment, which shall be arranged by the Contractor. The Department will exercise control over the Contractor in the choice of suitable material handling equipment and procedure to ensure safety of the equipments handled.
b. Anchoring of the equipment on the trailer/ lorry for safe transportation especially on slopes.
c. Transportation of the equipments to ACCF safely.
d. Unloading of the equipments on the foundation pedestal by using suitable material handling equipment.
e. Positioning of the tanks and pumps on proper foundation built during erection phase.
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f. Checking of level of the equipments by using U-tube water level, dial gauge and spirit level and correcting level difference, if any, by using metal shims of required thickness.
g. Connecting of the earthing boss of the equipments to the earthing pit.
h. Filling of the foundation pocket with non-shrink cement concrete.
2.2.3. Installation of pipeline
The installation of pipeline under scope of contractor comprise the
following :
a. The transportation of pipeline segments safely to IPRC from
Contractor’s site.
b. Unloading of the pipelines carefully so as to not damage the
hardware.
c. Ensure maximum segments are joined by welding and flanged
joints are avoided. The Department shall decide if at any
location flanged joint is necessary.
d. The welding procedure followed should be same as those given
in Section 2.1.2 above.
2.2.4 Testing,Cleaning and Painting
The scope of Contractor’s work are as follows:
a. All welded joints during fabrication and erection shall be qualified
as per procedure listed in Section 2.1.3, Volume-II.
b. The cleaning of system and painting of pipelines and other
components are to be performed by Contractor as per procedures
listed in Section 2.1.4 and Section 2.1.5, Volume-II.
2.3. Commissioning
After satisfactory erection, the FSS shall be commissioned in 2
phases jointly by the Department and the Contractor. The fluids
such as IPA and GN2 shall be provided by the Department at free
of cost.
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2.3.1. Qualification tests
The individual sub-systems of FSS shall be validated independently
in static condition (without flow) with inert fluids,GN2 for gaseous
systems. The procedure shall comprise the following:
a. Media substitution with GN2 and analysis to comply with the following specification: Moisture : 20 ppm Oil : 3 mg/m3 Particulate contaminants : Class IV of SAE AS 4059E
b. Functional check of all flow components (including evaluation of response time of EP and control valves)
c. Verification of all instruments
2.3.2. Final acceptance tests
The entire system shall be qualified together in dynamic (flow)
condition with the actual working fluids on the trial tank. The
procedure shall comprise the following:
a. The complete cleaning circuit shall be verified with respective use of pump(s) and cleanliness should be achieved till the level of Class 4 of SAE AS4059E & for oil contamination ≤ 3mg/m3.
b. Purging with hot GN2 for stage tank and analysis to comply with the following requirements: GN2: IPA : <5 ppm
Moisture : 20 ppm
Oil : ≤ 3 mg/m3
c. Filling of the systems with the respective working fluids and pressurizing to MEOP to validate structural integrity.
d. Flow trial to evaluate the flow characteristics of the circuits such as pressure drop and temperature rise at the working flow rates.
e. Functional validation of all flow components and instruments.
3 SAFETY, RELIABILITY AND QUALITY ASSURANCE Class 2B Ex d (flame-proof) level of safety according to ISO standard to
be maintained while fabrication and commissioning of system. Since the
systems are highly complex in nature, the philosophy and criteria to be
adopted shall be highly safety-and-reliability-oriented for their systematic
and proper functioning. The designs of the sub-systems, components,
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equipments to be carried out by the Contractor shall specifically address
essential safety provisions both in-built and external. Reliability is a prime
factor, which has to be embedded in the process of realization of the systems.
To ensure that the sub-system design, development, selection of equipment,
components, material, etc are in compliance with the standard engineering
practices, it is necessary to follow established design codes and standards.
The relevant standards applicable to the scope of work described in this
document are furnished here under. Wherever specific mention is not made
for particular application, the relevant and applicable procedures shall be
followed after mutual agreement between the Department and the
Contractor.
3.1 Safety assurance plan
3.1.1. General safety
Facility location as per established safety criteria, considering the explosion effects of test objects and run tank.
3.1.2. Safety in equipment and fluid circuit engineering
Use of vessel and fluid circuit materials compatible for the respective fluid medium, working temperature and pressure
Installation of safety relief valves for pressure relieving in emergency and connecting to vent/ disposal systems
Adoption of leak-tight joints in field circuits
Introduction of adequate filters for ensuring the specified particulate fineness
Compartmentalized operation of fluid circuits and isolation to contain damage by operating valves
3.2. Quality assurance
The reliability of FSS is a combination of specification of the equipments/ components, serviceability and maintenance of the same, which are meant to serve for a minimum period of 25 years for effective and timely preparation/ testing, which includes trouble-free performance of systems and sub-systems to the intended specifications.
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The Contractor must look for the quality factors individually
attributed to engineering developments, redundancy philosophy adopted,
selection of equipments and components, test and acceptance procedures
followed, repetitive performance achieved, risk analysis carried out, etc.
Ultimately, the reliability of the system is assumed to have been
achieved if all the equipments and components of the servicing facility are in
serviceable condition whenever the system responds to the commands
executed as per the definitions and specifications.
The expected value of probability of the trouble-free operation of
various equipments, components and also the total system need to be
estimated based upon their selection criteria and their past performance.
The quality assurance is an unified approach that attempts to control
the quality right from design stage to commissioning stage, which includes
the checking of the adequacy of the equipments/ components for materials,
fabrication, erection, testing. It is the combined responsibility of the
Contractor and Department to ensure that all possible failure modes are
exercised during the mock-up trials.
This may be ensured by following the general requirements as given
below:
Establishment and enforcement of standard engineering practice
Evaluation of products at each stage of development process
For the purpose of confirmation of the above aspects, the documents such as
functional documents and mathematical formulation document shall be
prepared and reviewed wherever applicable.
3.3. Material selection, standards followed for structures, pressure
vessels, piping etc
The steel structures shall be fabricated using standard rolled steel
sections such as channels, I-beams, angles, plates and rods. For mechanical
elements viz pins, shafts, etc, heat treated alloy steels shall be used.
Wherever the structural members are subjected to heavy loads and
dimensional stability is required, the structures shall be stress-relieved.
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The flow components, pipes, pipe fittings, etc used for the fluid circuits shall
be made of compatible materials like SS 304L/ 316L/ 321, etc.
3.4. Standards followed The following standards are used for component design, material
selection and fabrication. However, the equivalent standards/ codes in force
in the country of the manufacturer are also acceptable at the discretion of the
Department.
S No Description Standard/ Code
1. Piping ASME B 31.3
2. SS pipes ASME B 36.19
3. Butt welded fittings ASME B.16.9
4. Threaded fittings ASME B16.11
5. Flanges ASME B 16.5
6. Bolts, Nuts and
Washers
ASTM A 193/320 B 8, A 194 8
7. Gaskets API 601/ ANSI B16.5
8. Ball valves API 6-D/ISO 17292
9. Globe valves ANSI B.16.34/ API 6-D/ API 598/
ISO 15761(small)
10. Pressure regulators Manufacturer’s standard
11. Filters Manufacturer’s standard
12. Safety Relief valves ASME Section VIII Division I/ API
RP 520/ API RP 527
13. Pressure gauges BS 1780/ IS 3624
14. Flexible hoses Manufacturer’s standard
15 Pump Manufactures standard.
16. Pressure Vessels ASME Section VIII
17. Hydraulic pressure
test of pipe-lines
ASTM A 530
18. Pickling & passivation ASTM A 380
19. NDT ASME Section V
20. Welding ASME Section IX, AWS
21 Radio-graphy ASTM E 94
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4. DOCUMENTATION
The lists of documents to be provided by the Contractor at the different phases specified thereupon are outlined below and Contractor shall follow instructions as mentioned in Sl. 4.2.11/Volume-I for preparing relevant documents.
4.1. Design review
The Contractor shall submit a document listing their comments on the design document provided by the Department. If the Contractor proposes any alternative scheme or sizing, the detailed justification, along with calculation wherever necessary, shall be submitted. In case the Contractor proposes to employ alternative codes/ standards followed in their country, different from those specified in this document, the copies of such codes/ standards in English shall be submitted.
4.2. Detail engineering review
The level of information to be provided in these documents shall be as given in Section 4.2.2. volume-I
a. Pipe-line lay-out drawings
b. Pipe-line isometric drawings
c. Calculations for sizing and positioning of thermal compensators
d. Estimation of pressure drop
e. Estimation of temperature rise
f. QAP
g. Procedure and acceptance criteria for fabrication, erection and commissioning
h. Civil and electrical requirements
i. Purchase specification of materials
j. List of sub-contractors
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4.3. Fabrication
During the Pre-Shipment Review (PSR), the following documents shall be submitted:
a. As-built fabrication drawings
b. Test certificates and inspection reports of the materials such as equipments, flow components, pipes, pipe fittings, instruments (including the calibration certificates), etc
c. Wiring diagram of instrumentation and electrical systems
d. Test certificates and inspection reports of fabrication (including the radio-graphic films)
4.4. Erection
At the end of erection, the following documents shall be submitted: a. As-built pipe-line lay-out drawings b. As-built pipe-line isometric drawings c. Estimation of pressure drop and temperature rise based on the as-built pipe-line isometric drawings d. Certificates of tests (including radio-graphic films) done during erection e. Inspection report by the Department
4.5. Commissioning
At the end of commissioning, the following documents shall be submitted:
a. Certificates of tests done during commissioning
b. Inspection report by the Department
c. Final acceptance report (jointly between the Department and the
Contractor)
d. Detailed documents for Operation to comply with the specified test objectives
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Maintenance (routine, preventive and break-down)
Trouble-shooting
5. SUB-VENDOR DIRECTORY-MECHANICAL SYSTEM
The Sub-vendors, who, in the opinion of the Department, are
competent enough to deliver the materials or execute the services required
for establishment of the system, are listed below. In case the Bidder proposes
sourcing the materials/ services from Sub-vendors not covered in this
directory, the list of such Sub-vendors, along with their detailed company
profile, shall be provided in the bid. The list of additional Sub-vendors
proposed by the Bidder is subject to review, during evaluation of the bid, by
the Department, who reserves the right to accept or reject the proposal
wholly or in part.
5.1-Pipes & Pipe Fittings
SS pipes
1 M/s REMI Edalstahl tubulars Ltd., Mumbai
2 M/s Ratnamani Metals & Tubes Ltd., Ahmedabad
3 M/s Nuclear fuel Complex, ECIL, (PO), Hydrabad
4 M/s Maharastra Seamless Ltd. Jindal group company, Sukeli 5 M/s Sandvik Asia Ltd., Mumbai, Pune Road, Dapedi, Pune 6 M/s Jindal Saw Ltd. Nashik
5.2 Pipe Fittings
1 M/s Amforge Industries,Mumbai
2 M/s Echjay Industries,Rajkot
3 M/s Eby Industries, Rajghat,Gujarat
4 M/s J.K.Forge Industries,Mumbai
5 M/s Mechwell fittings Pvt. Ltd.,Chhatral mehsana (Dist.), India 6 M/s Sanghvi Forge Industries,Mumbai
7 M/s Chowdhary hammer works,Faridhabad.
8 M/s. Gujarat Infrapipes Pvt Ltd,
9 M/s. Metal Forge (India), Mumbai
10 M/s. Tube Products Incorporate, Vadodara
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5.3 Flexible Hoses
1 M/s Perfect Hardware Mart, Parrys/India
2 Proact IMS Pvt Ltd, Hanumanthnagar/India
3 M/s Huzefa Enterprises, Mannady/India
4 M/s Globe Engineering Associates, Madhavaram
5 M/s Vantage Technologies, BTM Layout 2nd Stage
6 M/s M.Babulal&Co., Nanubhai Desai Road
7 M/s Umac Avionics Pvt Ltd, Indiranagar
8 M/s STS Titeflex India Pvt Ltd, Doddaballapur
9 M/s Metallic Bellows, Chennai
10 M/s Gayatri Dimensions, Vadodara
5.4 Flow Components
Valves
Valves may be procured from the sub with a suitable collar flange.
5.4.1 Globe Valves (Manual, EP operated ) and Check Valves
1 M/s Ireland S.A.S, France
2 M/s VELAN , France
3 M/s Samson Aktiengesellschaft, Germany,
4 M/s Weka, AG., Switzerland
5 M/s JSC Cryogenmash, 67, Lenin Avenue, Balashikha-7,
Moscow Region, Russia
6 M/s Splav Modernizatsiya (Joint Stock Company)
7 M/s. ARCA-Regler GmbH, Germany
8 M/S. FEMA s.r.l, Italy
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9 M/s Flow serve India Controls Pvt. Ltd. Bangalore
10 M/s Samson Controls Pvt Ltd, Pune, India
11 M/s MIL control Ltd., Aluva P.O., Cochin
12 M/s. GE Energy (Dresser Valve India Pvt Ltd), Coimbatore
13 M/s Instruemntation Ltd. Palakkad, Kerala, India
14 M/s Indus vacuum & Cryogenic systems (STOHR
Germany) , Vadodara
15 M/S. Emerson Process Management Chennai Pvt Ltd, India
16 M/s. Severn Glocon India Pvt. Ltd. Chennai
17 M/s VELAN , Coimbatore,India)
18 M/s Indus vacuum & Cryogenic systems (STOHR
Germany) , Vadodara
19 M/s Ampo valves India Pvt. Ltd. Coimbatore
20 M/s WEIR BDK, Hubli
21 M/s Herose, Germany
5.4.2 Filters
1 M/s Puronics System,
3rd Phase Peeniya Industrial Area, Bangalore
2 M/s Ultra Filters (India) Pvt. Ltd, Basva Nivas, 29/2 K.H Road, Bangalore
3 M/s Milliipore Gesellschaft GmbH , A-1130 Wien, Austria
4 M/s Novintec Filters,Paris, France
5 M/s JSC Cryogenmash , Russia
6 M/s R&DIME, Russia
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5.4.3 Burst-Discs
1 M/s BS &B System (India) Ltd. 9 Cathedral Road,Chennai
2 M/s Fike Corporation
3 M/s Rembe GmbH
5.4.4 Safety Relief Valves
1 M/s Fainger Leser Valves Pvt. Ltd.Andheri, Mumbai
2 M/s Anderson Greenwood & Co. Stafford, Texas, USA
3 M/s Crossby Valve & Engg. Co. Ltd.,England
4 M/s Instrumentation Ltd.,Palakkad.
5 M/s Motoyama Engg Works Ltd, Japan
6 M/s IMI Bailey Birkitt Ltd, Manchester, England
7 M/s Bopp & Reuther, Germany
8 M/s Herose, Germany
9 M/S. Weir BDK Valves Pvt Ltd, Hubli, India.
10 M/S. FEMA s.r.l, Italy
11 M/s WEIR BDK, Hubli
5.4.5 Pressure Gauge
1 M/s Wika Instrument Limited, Pune
2 M/s. Baumer Technologies India Pvt Ltd, Chennai
3 M/s. Budenberg Gauge Pvt Ltd, Chennai
4 M/s. ASHCROFT India Pvt. Ltd, Chhatral
5 M/s. Swagelok
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5.4.6 Instrument Valve(Needle Type globe valve)
1. M/s Swagelok
2. M/s Parker
3. M/s Hoke
4. M/s FITOK GmbH
5. M/s DK LOK, Korea
6. M/s Microfinish Valves, Hubli
7. M/s L&T, Chennai
5.4.7 Pressure regulator
1 M/s Prabha Engineering Works,Karamana/India
2 Hind High Vacuum Co Pvt Ltd,Peenya Industrial Area
4 Micronel Global Engineers Pvt Ltd,Indiranagar
5 M/s GOODWILL CRYOGENICS,Navi Mumbai
6 M/s Excel System, Town Hall Road
7 M/s Globe Engineering Associates, Madhavaram
8 M/s Godrej & Boyce Mfg.Co.Ltd, Vikhroli
9 M/s Adams Technologies Private Ltd, Mahalingapuram
10 M/s Vaiseshika Electron Devices , Across tangri river
bridge
11 M/s Vantage Technologies, BTM layout 2nd stage
12 M/s Ram E&I systems Pvt Ltd, chennai
13 M/s Umac Avionics PTE Ltd, singapore
14 M/s Icon Enterprises, villivakkam
15 M/s Taiyo Nippon sanso K Air India Pvt Ltd, Navi
Mumbai
16 M/s Emerson Process Management Chennai Pvt. Ltd.,
Chennai
17 M/s Circor Flow Technologies India Pvt. Ltd., Coimbatore
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5.4.8 Command Bottle
1 Art Industrial School, Thoothukudi
2 Joe Industries, Nazareth
3 Jeya Engineering & Infrastructure Pvt Ltd,Tuticorin
4 Kasthiyar Industries, Nazareth
5 M.E.INBA ROBERT,Kanyakumari
6 M.M Shibu Engineering Contractor, Vadakangulam
7 Modern Tech Febrication & Engineers, Kanyakumari
8 Raji Engg.Co, Tirunelveli
9 RK Industries, Thoothukudi
5.4.9 Pump
1 SMD Pump & Engineering India PVT LTD
2 Sealing Tech INC
3 M/s SHREE HYDRAULIC ENGINEERS
4 M/s Keerthi Pumps
5 M/s M GOVIND AND SONS
6 M/s Janus Trading Co.
7 M/s WEIR BDK, Hubli
8 M/s Microfinish Valves, Hubli
5.4.10 Pressure Vessel( for Run Tank & Collection Tank)
1 BHARAT HEAVY ELECTRICALS LTD, Delhi
3 Hind High Vacuum Co Pvt Ltd, Bangalore
4 M/s ARF ENGINEERING LTD, Chennai
5 M/s. Sree Ramakrishna Engineering Enterprises,
Vishakhapattnam
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6 The Anup Engg Ltd, Gujarat
7 M/s Artson Engg Ltd, Mumbai
8 M/s L & T, Mumbai
9 M/s INOX India Pvt. Ltd., Vadodara
5.4.11 Spray Nozzle
1 M/s SMD PUMP & ENGINEERING INDIA PVT LTD ,
Chennai
2 M/s Spraying Systems (India) Pvt Ltd , Bangalore
3 M/s Spraytech Systems India Private Limited , Mumbai
4 M/s MARK TECHPRO & CONSULTANTS PRIVATE
LIMITED , Chennai
5A. SUB-VENDOR DIRECTORY-INSTRUMENTATION SYSTEM
S.No Items Recommended Vendors/Brands
1 Pressure Transmitters (Absolute & Differential)
Pressure Transmitter: Rosemount, SMAR, YOKOGAWA, HONEYWELL
1.a. Manifold for pressure transmitters
Parker/Swagelok/Anderson/Ham-let/DK-LOK
2 Temperature transmitter Smar, Rosemount,Honeywell
3 RTD Probes Tempsens, Auxitrol, Fabrica
4 Mass flowmeter E+H, Micro motion
4(A) Hart compatible hand
held communicator for
programming the
transmitters.
Global isntruments Grace infotech Nagman instruments & electronics (p) ltd Range enterprises Vantage technologies Fluke technologies pvt.ltd
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S.No Items Recommended Vendors/Brands
5 Solenoid valve M/s Asco, Chennai M/s Parker M/s Herion M/s Rotex M/s Thomson 6 Junction boxes 1. Legrand
2. Standard Metal Industries 3. Chemin controls , Pondicherry. 4. M/s Baliga Lighting Equipments
Ltd
5. M/s Flame Proof Equipments Pvt. Ltd
6. M/s. Stahl, Chennai 7. M/s CEAG Flame Proof Control
Gears (P) Ltd
8. M/s FCG Power Industries Pvt. Ltd 9. M/S. EX Protecta 10. M/S. Pepperl+Fuchs Pvt Ltd. 11. Weidmuller
7 PVC cables 1. Delton Cables, New Delhi 2. Paramount communication Ltd., New Delhi 3. NICCO corporation limited, Kolkata 4. Cable Corporation of India, New Delhi 5. CMI LTD, New Delhi 6. Incom Cables 7. Thermo cables Limited,Chennai. 8. Advance Cables, Bangalore 9. Tempsens Instruments Pvt Ltd, Udaipur.
20AWG 2 core armoured cable
20AWG 4 core armoured cable
18AWG 2 core armoured cable
18AWG 64 Core Cable
20AWG 64 Core Cable
18/20 AWG Single core PTFE wire (for internal rack wiring)
8 Cable trays 1. M/s Patny systems, Secundrabad
2. M/s Elcon Instruments, Pune
3. M/s Shruti Industries, Pune 4. M/s JK Enterprises, Chennai 5. M/s. VSL Instruments 6. M/s Sadhana Engineering Corporation 7. M/s Pro fab Engineers 8. M/S Instrument Cable Trays
Accessories for above cable trays
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S.No Items Recommended Vendors/Brands
9 Structural materials
10 Isolators Make: Pepperl + Fuchs & MTL Isolators for
transmitters.
Isolators for status
11 Relays Make: Phoenix
12
Power Supply 24V ±10% - 10 A- SMPS (Low ripple)
Make: Phoneix, Weidmuller, Lambda, Kepco
13
Connectors
Weidmuller, Harting, Trehotham, Phoneix
14. Instrumentation double rack
Presidant, Schneider, Rittal
15. Console Adharsha, Pyrotec
16 Power cable Finolex, Poly Cab, V Guard, RR Kabel, Havells, Lapp, Kundan
17 Earth cable Finolex, Poly Cab, V Guard, RR Kabel, Havells, Lapp
18 Terminal block 1. Wago
2. Phoenix
3. ABB
4. Weidmuller
19 Indicators , Switches
&Keys
1.Tyco; 2.Amphenol; 3.Honeywell 4.Swiztec 5. Siemens 6. Alstom
Indicators
Authorization keys
Switches with Indicators
20 MCBs Legrand, Havells
21 PLC based control
system including 3 user
PCs, operating
software, SCADA,
Printer, etc.
Siemens/ GE/ Allen
Bradley/Honeywell/Schneider/B&R/Sigma
tek/ABB/Mitsubishi
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S.No Items Recommended Vendors/Brands
22 Guided wave radar
based level sensor
Vega, E+H, Rosemount
23 Instrumentation Works 1.Chemin Controls Pvt ltd, Pondicherry 2. Measurecon Pvt ltd, Chennai
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6. GLOSSARY OF ACRONYMS, ABBREVIATIONS AND ICONS
6.1. List of acronyms
Acronym Full form
AC Asbestos Cement
ACCF Automated Continuous Cleaning
AISI American Iron and Steel Institute
ANSI American National Standards Institute
API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society of Testing and Materials
BG Bank Guarantee
BIS Bureau of Indian Standards
BOM Bill Of Materials
BS British Standard
BSP British Standard Pipe (thread)
CAD Computer Aided Design
CGA Compressed Gases Association (USA)
CI Cast Iron
CS Cast Steel
CR Control Room
CPM Critical Path Method
CTR Cable Terminal Room
DER Detailed Engineering Review
DG Diesel Generator
DN Diameter Nominal
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DP Differential Pressure
EOT Electrically operated Over-head Traveling (crane)
EP Electro-Pneumatic (valve)
ERW Electrical Resistance Welded (pipe)
FAT Final Acceptance Test
FCI Flow Control Institute
FH Fire Hydrant
FIM Free Issue Materials
FSD Full Scale Division
FSO Full Scale Output
FSS Fluid Servicing System
GA General Arrangement (drawing)
GI Galvanised Iron
GN2 Gaseous Nitrogen
GTAW Gas-purged Tungsten Arc Welding
HART Highway Addressable Remote Terminal
ID Inside Diameter
IPA Iso Propyl Alcohol
IS Indian Standard
ISO International Standards Organisation
ISRO Indian Space Research Organisation
LD Liquidated Damages
IPRC Isro Propulsion complex
MAWP Maximum Allowable Working Pressure
MEOP Maximum Expected Operating Pressure
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MS Mild Steel
MSL Mean Sea Level
MSLD Mass Spectrometer Leak Detector
MTBF Mean Time Between Failures
NAS National Aerospace Standards (USA)
NC Normally Closed
NDT Non-Destructive Technique
NEC National Electrical Code (USA)
NH National Highway
NO Normally Open
NPT(F) (American) National Pipe Thread Female
NPT(M) (American) National Pipe Thread Male
OD Outside Diameter
OS&Y Outside Screw and Yoke
P&ID Process and Instrumentation Diagram
PBG Performance Bank Guarantee
PCC Plain Cement Concrete
PCE Per Chloro Ethylene
PCTFE Poly Chloro Tri Fluoro Ethylene
PERT Project Evaluation and Review Technique
PID Proportional, Integrative and Derivative (controller)
PN Pressure Nominal
PPM Parts Per Million (by volume unless specified otherwise)
PTFE Poly Tetra Fluoro Ethylene
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PUF Poly Urethane Foam
QAP Quality Assurance Plan
QC Quality Control
RCC Re-inforced Cement Concrete
RF Raised Face
RFP Request For Proposal
RTD Resistance type Temperature Detector
SFD Schematic Flow Diagram
SL Sea Level
SLR Spring-Loaded Regulator
SMAW Shielded Metal Arc Welding
SOV Solenoid Valve
SS Sub-Station
SS Stainless Steel
SWG Standard Wire Gauge
SWL Safe Working Load
Sch Schedule
TC Thermo Couple
TCE Tri Chloro Ethylene
TPI Third Party Inspection (agency)
URL Upper Range Limit
WT Wall Thickness